With our cabinet project on hold (the oak is still in the kiln), I've done some repairs to a beautiful two story deck. The owner will be having an event at the house soon, and was re-staining the deck, when he decided that some of the pieces should be replaced.
Upon inspection, some of the decorative members on the railing posts and king posts were indeed due for replacement. Even though the railing system is quite intricate, I was able to disassemble the puzzle, make duplicates of the parts to be replaced, and install the new. Most of the pieces had a 1/2" round over on the edges, which was achievable with the router. The owner was then able to finish staining the deck, which turned out beautifully! It will last for many more years, and was well worth the time and investment to repair.
Here are some before and after pictures.
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