In this episode, I help a Colorado Springs Client remodel their staircase. The existing staircase was a straight run with an outdated style. I redesigned it to have open-ended steps with a craftsman handrail.
Summary
Building a Custom Staircase with a Handrail
When a client wanted to modernize their outdated staircase to match their new hickory flooring, I took on the challenge of transforming it into an open-ended tread design with a custom handrail. Here’s how I tackled the project—from demolition to final installation.
Assessing the Existing Staircase
The original staircase had a dated design that didn’t complement the new flooring. The clients wanted an open-ended tread style, which required significant modifications. Before installation, I had to:
Since the drywall corners were fragile after demolition, I reinforced them by sliding in new framing between the stringers and drywall and securing it to the existing studs.
Fabricating Custom Components
To ensure a seamless fit, I pre-fabricated most of the staircase components in my workshop.
While custom-sized treads could be ordered, local millwork shops couldn’t accommodate the exact specifications needed to wrap around the existing walls. So, I milled my own:
For the open-ended treads, I cut miters on the table saw. The bottom tread required a notch for the newel post, so I:
To match the home’s existing door panel design, I built a newel post with the illusion of floating panels:
The post featured three horizontal rails (bottom, middle, and top) to match the home’s interior doors. For consistency, I used a spacer block to align the middle rails perfectly.
The decorative cap required precise miter cuts to meet cleanly in the center. I:
Prepping the Spindles
With 20 spindles and cross braces to assemble, efficiency was key:
Joinery with the Domino
While some woodworkers debate using a Domino joiner, it was a game-changer for this project. With 72 mortises needed for the cross braces, it saved hours of work. I:
Final Assembly & Installation
Once all components were ready, I:
Lessons Learned
Hickory is tricky—it splinters easily, so careful milling and routing techniques are essential.Pre-finishing saves time—staining and sealing components before assembly prevents missed spots.Always check building codes—misinformation is common, so refer to official sources to avoid costly mistakes.The Finished Staircase
The final result was a sleek, modern staircase that perfectly complemented the home’s new flooring. Every custom detail—from the handrail to the newel post—was crafted for both aesthetics and durability.
