The Banister

In earlier posts, you have seen the transformation of the trim throughout the house from stain to painted white.  We had discussed doing this to the banister which separates the raised living room from the dining room and kitchen, but knew it would be a much more difficult job than just slapping a coat of paint on top of it.

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A good picture showing the banister behind the furniture still has the light stain that we replaced everywhere else in the house

The ultimate plan was to have the uprights painted white and stain the top railing.  But doing this would mean removing the railing and a lot of slow steps.  The first thing I did was prime and paint the uprights with the railing still attached.

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Next, I removed the top railing and continued to paint the railings.

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It was sort of scary walking down the stairs for several weeks as we feared we would be impaled if we lost our footing.

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Yikes

After setting the railings on saw horses in the garage, the next step was to clear away the coats of paint and stain to get the wood ready for staining.

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I first thought I would need to use a belt sander to clear the stain, but we visited my parents in Iowa and my dad introduced me to a tool I had never even heard of: An Electric Planer.

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Planer borrowed from my dad (this thing is really loud)

This planer was great!  It did in seconds what a sander would take hours to accomplish.

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Wood is planed, sanded then cleaned to get ready for staining

We decided to go with a black cherry wood stain to match other furniture in the house.

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Slow application process.  Many coats.

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It took about five coats to get the color the way I wanted it to look.  Next step: clear coat.

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Notice the awesome key-shaped folding knife. A random find at Harbor Freight

I added about four coats of clear to the wood.  I went too fast on the first coat and got bubbles, which I had to sand down.  I went slower with my brush on later coats to avoid this problem.

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With the railings stained and clear-coated, the next step was to attach the railings to the uprights.

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The best way I figured to do this was to pull off the uprights and nail them to the railing on the floor.  It would have been too awkward trying to nail hardwood while hanging over an edge.

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These are the tools I used.  Hammer, drill, finishing nails, a nail set and a rubber mallet covered in a sock to pound off the painted uprights.

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I drilled out each hole before pounding a nail into place.

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Sara sanded rough areas from my paint job on the uprights while I secured them to the railing.

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After we had all of the uprights removed, Winnie and Robert enjoyed some play time in the living room.

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We had some help securing the finished sections into place.  Sara’s parents and brother came up for the afternoon to lend a hand.  They helped hold the sections while I nailed them in.

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After the banister on the top was in place, we were left with the ugly problem of cutting a piece of wood to cover the hardwood floor the previous homeowner put on the stairs.  If you look closely at the picture below, you can see the edges of the hardwood are exposed.

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I measured a bunch of times then cut out a piece of 1/8″ plywood underlayment.  I had to use a coping saw and cut it by hand because the wood was so thin that it would shake apart if I used an electric jig saw.

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Cutting the wood by hand, there were imperfections, which I sanded down.

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After several rounds of holding the wood in place, marking it and sanding more off, it was ready to be nailed into place.  This means nail gun time!

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I pained the new piece of wood white then secured the banister the same as I did with the others.

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I used a combination of nails and screws to hold the uprights to the railing.  I used screws where I thought it needed some extra strength.  But this left a big problem: Ugly holes all over the banister.

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Some Elmer’s wood filler was just the trick.  I added more than I needed, then sanded away the excess and painted again.

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The finished product!

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Tada!

Winnie now has a beautiful banister to look at when she terrorizes our kitchen.

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The Leaky Faucet

There are a great deal of projects we hope to get finished in our yard this summer.  Many of them require having water. (cleaning gutters, planting grass, etc.)  Unfortunately, our existing water faucet leaked heavily anytime we turned it on.  We were worried about so much water pooling so close to the foundation.  This made fixing the water spigot a top priority.

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Water sprayed from two places whenever water flowed.  It leaked from the handle and also from the hose bib vacuum breaker (where the hose attaches)

I was able to fix one of the leaks by tightening the packing nut just beneath the handle.  That was fairly simple.  However, the other leak was more complicated because it would have required a part I could not find at either Home Depot or Menards.  The rubber seal inside the vacuum breaker was completely shot.  (photo below)

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The seal on the hose bib vacuum breaker was shot. This meant water would spray through small holes in this device anytime the water was turned on.

I had trouble finding a replacement because the thread on this is 1″ in diameter.  Most typically come with a 3/4″ thread (click for example).  People I spoke with also said I would have a hard time finding a replacement rubber seal.  So after much frustration, and many weeks weighing my options, I decided to replace the entire unit.  It was not going to be as easy as unscrewing the old faucet and fastening a new one.  I would have to learn how to cut brass and solder a replacement.  I was lucky enough to have a shutoff valve just inside the house so that in the event that I needed to call for professional help, we could continue flushing toilets while we waited.

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The shutoff valve for the faucet is about 2 feet away from the exterior wall leaving me plenty of space to work

To learn some DIY plumbing skills, I enlisted the help of my Dad.  Over the course of my lifetime, he has remodeled every room of their home, which was built in 1889.  We happened to be visiting them in Iowa and spent some time learning how to cut and solder brass.

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He taught me to use a propane torch to heat the brass until it starts to change color

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He also taught me to clean the brass and prepare it using flux, which sucks the solder into place for a tight seal

See what I learned about applying soldering in the following video:

 

After giving me the “mental” tools to do the job, my dad also sent me home with some of the physical tools I would need (brush, flux, pipe cutter).  After arriving back in Minnesota, we didn’t waste much time getting to work.

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Old water faucet removed by cutting brass pipe on the inside of the house (water shutoff valve safely closed)

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The pipe is secured in my vise so I can remove the old faucet and reuse the brass pipe

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Fire it up!

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Heating the pipe to melt the old solder so I can remove the leaky faucet

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What the old faucet looks like

We had replacement parts standing by.  In the series of photos below, you will see how I am using a different strategy mounting the new faucet to the pipe.  Instead of soldering it directly to the brass pipe, I am attaching a thread to the pipe, so I have the option in the future of replacing the faucet head if it leaks in the future.

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A new brass sillcock and several fittings to attach everything together.  You also see a part of our banister sitting on the workbench (stay tuned for exciting future post!)

As I learned from my dad, I prepared each pipe I would be soldering by brushing it down, then applying flux with a small brush.

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This pipe needed to be brushed on the outside.  You can see the container of flux just behind it.

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The threaded piece that will go over the pipe needed to be brushed from the inside

After applying heat until the metal started to change color, I touched the coil of solder to the brass and the flux sucked it into place.  I have one fitting ready to go!

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My first successful soldering job!

After the fittings were soldered into place, I made three revolutions around the threads with plumbers tape (which I later found wasn’t enough) and tightened the sillcock (faucet head) into place.  The nearly-finished product below:

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The pipe with attached faucet is ready to be put into place.  It’s had about 30 minutes to cool.

Adding the extra threaded piece made the pipe longer than it used to be.  This meant I would need to shorten the pipe next to the shutoff valve, or have the entire thing stick out of the house about an inch too far.

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I used a piece of metal flashing to protect the wood in our basement from the heat of the propane torch.

After the cut is complete, we just need to line up the two ends, make sure the faucet is facing the correct direction on the outside of the house and solder the two pieces together.

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All sealed!

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Another view of the finished product inside the basement.

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As you can see, the previous owners thought that caulk was the only solution.

I waited about a day before sealing around this because I wanted to check for any leaks.  I did have a minor drip from the sillcock, but that was resolved after I applied 5 layers of plumbers tape instead of just 3.

Click here to see the second spigot I fixed.

-Mike