Patch Old Baluster Holes

What happens in this clip

Before installing new stair parts, patch the old baluster holes on the stair treads. First, use a drill with a Forstner bit to enlarge the existing baluster holes. To prevent the drill bit from wandering, place a wooden guide block with a pre-drilled hole of the correct size over the existing baluster hole, centering it precisely. Then, drill through the guide block into the stair tread. Apply wood glue around the edges of 1-inch diameter, 3/16-inch thick oak plugs and tap them into the newly enlarged holes using a hammer until they are flush. Once the glue is dry, sand the patched areas smooth with an orbital sander to prepare for the new baluster placement.

Step 3 of 6: Prepare New Baluster Mounting Points

Remove any old adhesive, paint residue, or wood splinters from the mounting surfaces. Use a scraper or sandpaper to create a smooth and clean surface for the new baluster attachments. Ensure the holes or mortises where the balusters will sit are clear of debris.

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Every video in Baluster Replacement

1. Step 1: Measure Existing Balusters

   • 0:49–2:09 Measure and Mark New Baluster (Using Existing Template)
   • 2:14–3:03 Size New Balusters
   • 0:24–0:40 Measure and Mark Baluster for Cutting

2. Step 2: Remove Existing Balusters

   • 0:16–0:29 Remove Old Wooden Balusters
   • 0:08–0:23 Remove Old Balusters and Clean Area
   • 1:31–3:50 Remove Old Balusters and Nails

3. Step 3: Prepare New Baluster Mounting Points

   • 0:17–1:26 Patch Old Baluster Holes (this video)

4. Step 4: Cut Wrought Iron Balusters

   • 0:07–0:08 Cut New Iron Balusters to Length
   • 4:17–5:02 Cut Your Balusters
   • 0:15–0:25 Remove Old Balusters & Cut New Baluster

5. Step 5: Install New Balusters

   • 3:41–5:00 Install Metal Balusters and Caulk
   • 0:06–0:08 Insert Balusters into Rails
   • 0:04–0:16 Install and Secure Iron Balusters

6. Step 6: Inspect and Finish

   • 6:38–7:50 Final Inspection and Cleanup
   • 0:16–0:27 Final Alignment and Quality Control
   • 0:18–0:26 Final Inspection and Cleanup