- Joined
- Apr 14, 2014
- Messages
- 3,510
A little over 10 years ago we had a new deck put on the family cottage. When we got the price for the railings I almost had the big one. I decided it would be a good project to build it from scratch. Not being a great welder I cut all the parts to spec and took them over to a friends shop to have him do the welding.
I was pretty happy with the results and loaded the sections into the trailer to transport them to the cottage. I thought it would be a good idea to show them to the wife before painting them. That's when I got a rude awakening. She thought the raw welds looked terrible and suggested I dress them up on the mill.
Two weeks later they were nearly ready for paint. I beveled all 4 surfaces where each stile is connected to the top and bottom rail. The majority of the work was done with a 3/8" ball end mill with the finishing touches completed with a die grinder and deburring disks. In all there was a little over 1,000" of surface to be milled and finished. It only took 2 end mills, but close to 40 deburring disks.
Raw welds
Milling complete, next step polishing
Project complete
I was pretty happy with the results and loaded the sections into the trailer to transport them to the cottage. I thought it would be a good idea to show them to the wife before painting them. That's when I got a rude awakening. She thought the raw welds looked terrible and suggested I dress them up on the mill.
Two weeks later they were nearly ready for paint. I beveled all 4 surfaces where each stile is connected to the top and bottom rail. The majority of the work was done with a 3/8" ball end mill with the finishing touches completed with a die grinder and deburring disks. In all there was a little over 1,000" of surface to be milled and finished. It only took 2 end mills, but close to 40 deburring disks.
Raw welds
Milling complete, next step polishing
Project complete