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Question, building new open stairs for our home, design includes square spindles that support the hand rail going through the outer edges of the treads. Treads are 1 and 5/8 inch thick white oak and so far no luck making one inch square hole for spindles to go through the tread and entend below. Currently trying one inch round hole and corner chisel to make the square hole. One inch morticing chisel did not work, could not push through the oak.
If this does not work then thinking of using 3/4 inch round hole in tread, cutting the square spindle into two pieces and making round tenion on the ends to fit into round hole in treads. The spindles are 1 inch square white oak. Also would need the round tenion to end in a flat surface so the the spindle will fit flush witht the tread giving the appearnce the the square spindle goes through the tread ( the other part of the spindle would be attached to the bottom of tread). Is their a tool to make round tenions that I need from the square spindle?
Other suggestions on making square one inch hole?
Good news is that six posts were replaced yesterday as part the stair project. This is a post and beam house ( I think it is a Lindal Ceder Home from 1970's), removed six white ceder posts and replaced them w/ 3 1/2 X 4 inch black walnut.