Spindle Turning on Lathe

**gatz** · May 7, 2023, 08:07 PM

After viewing the video and description of Vlado's Spindle Turning , I thought I'd add my version.
This was done a number years ago for our nephew and niece's 3-story house. The stairway was missing 4 or 5 spindles and they asked if I could make new ones (of course I always like a challenge ha ha)
Found some 1" square oak blanks at Mennard's (IIRC) which were just the right size and even had extra length.

Took one of the existing spindles out of the stairway and measured every 0.10 inches for half the length to define the contour. Only half was needed as the spindle was symmetrical at about center. Made a poly-line drawing in ACAD and with a little massaging got it smoothed out. Had one of the guys in the shop cut the profile on a CNC. The template was mounted to brackets on the front of the JET 14x40 lathe.
A circular saw was mounted to a liner bearing slide acquired from somewhere...kinda forgot. Adjustment was done through stops and an indicator was used for repetitive cuts.

A vacuum was routed in behind the lathe bed and under the saw blade to pick up the dust & debris as the saw did its work.
Because the 1" square was spindly, pun intended, I had to devise a way to support the piece about mid-length. So, much time was spent designing and making a 4-jaw "chuck" which rode in a brass ring. By screwing in a threaded adjustment ring the 4 jaws were pushed against the 1" material and cushioned with tape; thus supporting it while turning. Also, on the tailstock end, another support was made to hold the material at that end; just a round piece of steel with 4 dowels and a center drilled hole.
All this worked great and nephew & niece were pleased with the results.