Mass-Producing Styrofoam® Balusters

James Brewczynski


Identical balusters can be mass produced economically for stage use by turning high-density Styrofoam® on a drill press. While turning wood requires expensive material and skilled labor, this method replaces the wood with inexpensive Styrofoam® and simplifies turning by using a profile pattern. The task is accomplished in three steps: building the Styrofoam® blanks, building the profile pattern, and turning the blank on a drill press.


1. Cut a ⅜″ dowel three inches longer than the baluster and chamfer one end. The dowel later serves as a centering device during installation. To help secure the foam to the dowel, imbed appropriately sized finish nails into ...

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