We are in the middle of a project that has a gorgeous view, and a direct South West exposure to the elements. We decided to make our paint grade columns out of a plastic wood called Azek.

Here is a picture of my shop with the plastic lumber ready to go. Yes, it is a small shop! I have to be thoughtful about how I sequence the work.

Half of the columns will be less than 8′ tall, so I start by trimming the panels to length with a cut off jig and a circular saw.

Then I rip all of the panels to width.

Next I cut the styles for the recess panel frames to length. One reason I like working in the shop is that I have my stationary tools connected to a dust collection system. Routing the edges of the style and rail more than filled a metal garbage can.

Here is a picture of a face with the style and rail.

After gluing up the panels we miter the corners and add a spline. The spine helps align the joint and provides more glue surface. I over cut the miter so the outside edge is tight, so there is a small gap on the inside of the joint. The spline makes up for some of the lost glue surface. I find when I spline a corner I do not need to pin nail it. If I need pins at all I will use 18 gauge stainless steel nails. In this case tape was all we needed.

Here are some box columns ready to be delivered to the site.

These sloped caps go on top of the crown mold, under the box beams.

These columns are looking great! 

Next it is off to the site for installation and the final trim.

All for now,

Dwight

Dwight