DIY Network

Steel Post Cover-Up From "DIY to the Rescue" episode DTTR-401F

Before: The bright steel support post was particularly jarring to the eye and conspicuous within its darker surroundings.

Support beams are standard in basements, but the Bakers dislike the unsightly appearance and want something that blends with the surrounding wood surfaces.

Materials:

(10) 1 x 8 x 8 solid pine boards
2!| x 2!| 3/4" plywood
Table saw
Miter saw
Scroll saw
Pneumatic nailer and compressor
Construction adhesive
1" finish nails
Stain
Wood filler
Carpenter!|s glue

advertisement

After the Rescue, the support post is camouflagued by warmly stained wood that blends with the English pub-style bar and custom entertainment center.

1. Measure the diameter of the posts. In our case the dimension is 3!?. In order to attach the surface boards, we must create cleats that fit around the posts. The cleats are made by cutting 5!? squares from scrap 3/4" plywood.

2. Draw a 3!? circle in the center of the 5!? squares using a compass of a jar lid. Then, draw a diagonal line bisecting the square into two triangular halves. Cut along the diagonal line with a jig saw to create two halves. Cut the circle on a scroll saw by following the curved line on each triangular part. Repeat this process for a total of 8 triangles.

3. To attach the cleats, add construction adhesive to the inside of the curved cut and along the diagonal cut, as well as the surface that contacts the floor or ceiling. Place the cleats around the post to create a square at the top and base of the post.

4. Add the second cleat in the same manner. Be sure to turn the seam perpendicular the other cleat for added strength. With cleats in place, it's time to cut surface material.
   
   
5. Beginning with 1 x 8 x 8 boards, cut a 45?a angle on both outside edges using a table saw. The width of the finished board must be 5-3/4" to fit around the 5!? cleats.

6. Cut each board to length using a chop saw or circular saw. Add glue to outside edge of each cleat and stand the boards in place.

7. Drive 1" finish nails through the surface board into the cleat. Add glue to the beveled edge where the surface boards touch, place the second board and drive nails every six inches from top to bottom.

8. Use colored wood fill to patch the nail holes. Allow several hours for the wood fill to dry, then sand the column with fine grit sandpaper. Wipe the column with a rag to remove dust.

9. Apply stain with a rag rubbing with the grain. Allow several hours for the stain to dry before adding finish molding to the top and bottom of the column.