Handyman Steve: June 2009

This week’s project is to replace the posts on the front porch. Since the existing porch posts are rotting and only 4 x 4 cedar, I’m going to make 6 x 6 cedar box columns with new trim & base. Let’s take a look at how this was done.

The first step is selecting the best pieces of 1 x 6 cedar that could be found at the local Home Depot. Here is where we are looking for the straightest pieces with the fewest knots.We will also need some 1 x 2 & 1 x 8 cedar for the trim.

Now we are going to mill the 1 x 6 to create a pinwheel tongue & groove.

Since we are painting these columns we are going to use the smooth side out.
After the columns are assembled using polyurethane glue (because it’s waterproof) we putty any knots and imperfections using a catalyzed wood putty to get a smooth finish for painting.

This putty is similar to Bondo and good for filling large knots and holes. It can be found at most home centers and hardware stores. Now the columns are sanded smooth and cut to size making sure that both ends are cut square. Once they are cut and sanded a coat or two of primer paint (use exterior grade) gets them ready for installation.

The next step involved removing the old columns without damaging the fascia board and skirt board. As it turns out, it was easier the take off the skirt board without disturbing the fascia, and a good opportunity to clean up and prime these pieces. Once that was complete and the skirt board was replaced the columns were ready to install. A cedar block that fit inside the column was fastened to the concrete with Tapcons and a plumb bob to locate the blocks. The column is then placed over the block and fitted in behind the skirt board which took a little persuasion with a hammer and a block of wood and once in place and leveled they are nailed in place.

The next step was to mill the trim. The 1 x 2 is chamfered on 2 edges and the 1 x 6 base trim chamfered on the top edge.

Some additional trim was needed behind the skirt board and around the top of the columns and some 1 x 1 cedar was cut for this.

To dress it up a bit some 1 x 8 cedar was cut to make some keystone type capitals which also served to cover the seams in the skirt board.

Once all the trim is fitted and nailed some caulk was used to fill any gaps and nail holes and now it’s ready for a couple of coats of paint which will take place when it stops raining. Until then see the pictures below for the almost completed porch project.