My customer wanted something different for their deck. Something other than 2×2 ballisters. I used 1×4 cedar , made a patern with1/4′ masonite and used my router table to shape the ballisters. 2×4 cedar top and bottom rails, back screwed the ballisters to bottom rail with the top fastened to a 1×21/2″ sub rail. Sub rail is fastened to 4×4 post and then rabbited top rail is fastened to sub rail from underneath
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Finished top rail with 11/4" back screwed from underneath
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Side view of completed rail
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The finnished product. 91 ballisters, 3 3flute straight bits,a lot of shop work and one day of assembly.
