Custom Curved Hickory Stair Treads and Risers in Central Oregon
This custom staircase project involved building curved hickory bullnoses and risers to fit an unusually shaped set of steps. The work required custom forms, bent lamination techniques, and careful staining and finishing to match the home's existing hickory flooring. From preparing the wood in the workshop to the final finish, each component was made specifically for this staircase.
Building Custom Curved Stair Components
The project began with building custom forms to shape the curved bullnoses and risers. These forms needed to hold the wood securely during glue-up while maintaining the precise curves required for the staircase. Frank applied lacquer and wax to the forms to help prevent the laminated wood from sticking.
The hickory boards were then cut into thin strips that could bend around the forms. Each strip was numbered and positioned carefully to help align the grain in the finished pieces. The bullnoses required multiple layers of hickory, with different thicknesses to accommodate their shape.
Each assembly was glued and secured with numerous clamps, then left to dry before the next steps could begin. With 12 separate glue-ups and careful timing between stages, the process required patience and attention to detail.
Shaping, Staining, and Finishing the Hickory
Once the laminated pieces had dried, Frank removed them from the forms and began sanding and shaping the curved components. The goal was to achieve smooth, consistent curves while preserving the natural character of the hickory grain.
Matching the existing floor was another important part of the project. The home's hickory flooring had a medium-brown stain and distressed finish, so the new bullnoses and risers needed to complement both the color and texture. Frank used samples of the existing flooring as a reference while adjusting the stain and distressing.
After the finish was applied, the completed components were ready for installation. Building the pieces in the workshop allowed Frank to work through the complex shaping and finishing process before fitting them to the staircase.
Custom Staircase Woodwork and Finish Carpentry in Central Oregon
Custom curved stair components are one example of the detailed woodworking and finish carpentry Frank L. Garrett Construction provides throughout Bend, Redmond, and Central Oregon. Projects range from new staircase details and railing updates to custom mantels, cabinetry, interior finish trim, and one-of-a-kind furniture.
Whether working on building a new home or updating an existing space, we focus on careful fitting, quality materials, and finishes that complement the surrounding home.
Contact us through the website or give us a call if you have a woodworking project you’d like to discuss with Frank.