DIY Network

Creating Fluted Columns From "Weekend Remodeling" episode WKR-304

After: An handsome portico with a dash of panache!

With the canopy soffit, beams and box trim in place, host Fuad Reveiz creates fluted columns.

Remember, on a project difficulty scale of 1-5 (5 being most difficult), the overall project rates a 2.

Materials:

Custom-fabricated canopy/awning
1 x 6, 1 x 8, 1 x 4 and 1 x 2 lumber
A variety of molding
1" trim
Silicon caulk
1/4" birch plywood
Cotton gloves
Paint
Wood putty
Anchors
Tape measure
Level
Hammer drill
Hammer
Trim nailer
Brad nailer
Circular saw
Hand sander
Cordless drill
Router
Speed square
Framing square
Painting supplies
Chop saw
Clamps
Table saw
Utility knife
Screwdrivers
Shims
Stainless steel screws

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G

1. Measure for the height of the columns and cut 1 x 8s to the correct length on the miter saw.

2. Next, it's time to use the router to add flutes to the faces of all four sides. Measure up from the ends -- making sure to leave areas for bottom and top trim -- and mark a line. Mark a second line about 1-1/2" from the first.

3. To create the design, place a 1-1/4" spacer between the 1 x 8 and a brace that's been nailed to the work surface. Clamp the 1 x 8 down and start routing the first outer flute. When the end is reached, stop at the first line. Turn the board around, clamp down and route the other outside flute (figure A).

4. To route the center flute, remove the clamps and spacer. Push the 1 x 8 against the guide, take a 1/2" spacer and set atop the 1 x 8. Clamp down. This time, route to the second pencil line to create a center flute longer than the outer flutes.

5. With all of the boards routed, rip 45-degree angles down the backs for a good corner fit.

6. To assemble the columns, first clamp a fluted board face down. Add wood glue to the mitered corners on one edge of two boards. Nail two boards together. Turn the boards over and nail through the opposite side of the corners (figure B). Repeat this process until 4 half columns have been created.

7. Measure n 1" from the front and side of the porch and mark for the base of the columns.

8. Install a block of treated lumber onto the porch surface, next to the lines (figure C). This is the block atop which the fluted columns will sit.

9. Over the larger block, center a smaller one to which the columns will be attached (figure D). Nail in place.

10. Under the canopy, install a small brace the small distance as the smaller block on the porch.

11. To install columns, set half-section in place on top of the larger block (figure E). Nail it into the smaller block. Remove the temporary support, then nail into the top block.

12. To complete the column, add wood glue down both mitered corners (figure F), then set other half of column in place and nail into blocking. Use brad nailer to secure all corners together over the length of the column (figure G). Repeat for all columns.