DIY Laminated Posts

Preparation

• 1

  Mix auto body filler 6 parts putty to 1 part hardener and fill any inconsistencies or seams in the post's surface using a flexible putty knife. Allow this to harden for 30 minutes.

• 2

  Sand the surface of the post thoroughly, so that all four faces are smooth and the corners are crisp, using a belt sander and 120-grit sanding belt. Dust the post using a paintbrush to remove the putty and wood dust.

• 3

  Measure the height and width of the post carefully on all four faces. Cut laminate to fit each face, one-half inch larger in all directions.

• 4

  Use a rafter square to mark off one-quarter inch at the top and bottom ends of each piece, on the back of your laminate. Clamp a piece of 1-inch thick lumber with a straight edge to the laminate with a C clamp, with the board's edge along the line on the bottom side.

• 5

  Install a flush-cut router bit with a bearing and adjust the router's depth to one-quarter inch. Start the router and run it left to right along the board to cut off the laminate. Repeat this for both ends of all four pieces.

Installation

• 6

  Roll a coat of contact cement onto two opposite sides of the post and the backs of their corresponding pieces of laminate, using a medium-nap paint roller. Use a heat gun on a medium setting to heat the glue to dry. Allow it to dry to the touch.

• 7

  Fit the two pieces to the sides of the post, tapping it in place with a rubber mallet. Use the router to trim the sides flush with the face of the post along both edges and as close to the top and bottom as possible. Run a mill bastard file against the face of the post that is not laminated to trim the laminate flush at the top and bottom on both edges of the two faces.

• 8

  Roll contact cement onto the remaining faces and install the laminate in the same way. Trim the edges with the router and run the file at a 45-degree angle over the seam to smooth the edge.