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Once again, I said yes to a friend (it seems I say yes to lots of my friends) who wanted me to duplicate some woodworking in a house he is rehabing.
So, I began a quest for the perfect way to make these balusters using power tools (the ones with cords). Looks fairly straightforward…the crank moves the router carriage along the workpiece while simultaneously turning the workpiece, and the ratio between the various gears determines how tight the spirals are. I have seen the future with my own eyes, and it is mechanical with chains, sprockets and plywood.
Its always a great experience to build a machine, if it turns out to be able to do what it was supposed to do. Christopher Schwarz has helped many of us solve some pretty frustrating problems over the years.
Always be yourself because the people that matter don't mind, and the ones who mind, don't matter.
Following Joe's lead, I would ask Santa for a insert plate with router attached, then build my own bench top router table.


I have the same router table and have found it very enjoyable to use since I was not in the mood to build a custom unit and I wanted a small tabletop version for the time being so I can easily move it out of the way when not in use.
It does have one flaw in its design (most all do) that can easily be overcome with a pair of small (2-inch) C-clamps. The entire unit assembles very quickly using included Confirmat screws and I had no issues during my assembly when I purchased my unit a few years ago. Anyway, I'm on a lot of vendor email lists and Rockler had a table blank they would have turned into a router table except someone spilled paint along one edge. He and his buddy, Fred Matlack, came up with this very clever tool and it looked like something I could make. What impresses me the most is that somebody actuallly pulls themselves together and build such a thing. Sadly enough, I never find much use for these machines later on, but building them is one of the things I like a lot about woodworking.
I made a table from a $10.00 blank top and scrap lumber recently; can't get much cheaper than that!


I've built lo-cost router tables from plywood (Baltic Birch and phenolic sandwich are best), as well as damaged counter tops from Lowes. I found a couple of tools that would do what I wanted, but one of them was extinct and the other cost a lot of money. I am equally impressed when people makes their own engines, eventhough they are also pretty simple machines. I like hand using hand tools as much as the next woodworker but this seemed like a nightmare coming to life.
I would need to practice on other woods before I broke out the mahagony (the wood used in the rest of the staircase).



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