Reader Project: Carpeted Curved Staircase Rebuilt in Solid Red Oak

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Gus B. of Edmonton pulled the carpet off the curved staircase in his home and replaced it with solid red oak treads and oak plywood risers. Because the stairs curve, no two treads near the bottom were the same — he ended up making four separate paper patterns to get them to fit.

The job took about a month of on-and-off work and ran roughly $800 to $1,000 in wood, glue and Bona polyurethane. Treads are 3/4-inch red oak with glued-on bullnoses, risers are 1/4-inch oak plywood, and everything was stained and finished in the shop before being set in place with Mapei Ultrabond.

In Gus’s words

I removed all the carpet on my curved staircase. I installed solid 3/4 inch oak to treads and used 1/4 inch oak plywood for the risers. I had to cut off the bullnose on the stairs and fill the inner stringers with oak plugs where the bullnose had been.

I needed to make 4 different patterns for the treads as the ones near the bottom were all different. I cut and fitted all treads before applying stain and Bona Polyurethane. I installed the risers followed by the tread starting from the top. Mapei Ultrabond was used to attach the risers and the treads.

The build

  • Project type: Built-ins & home improvement — staircase remodel
  • Skill level: Advanced
  • Wood: 3/4" red oak and 1/4" oak plywood
  • Finish: Stain and Bona polyurethane
  • Tools: Table saw, Festool Domino, router, paper patterns
  • Time: About a month, off and on
  • Cost: Roughly $800–$1,000 including wood, glue and Bona polyurethane
  • Plans: None — all his own work converting the existing stairs to oak

Biggest challenge

Hardest part was putting plugs in inner stringers and definitely making the different patterns for the stairs.

Photos

The finished curved staircase in stained oak, seen from the entry.
The finished curved staircase in stained oak, seen from the entry.
Looking down the finished treads from the top of the curve.
Looking down the finished treads from the top of the curve.
The starting point: carpeted curved stairs with the covering pulled back on two treads.
The starting point: carpeted curved stairs with the covering pulled back on two treads.
Carpet, pad and tack strip removed, with the old bullnose being cut away.
Carpet, pad and tack strip removed, with the old bullnose being cut away.
The inner stringer where the bullnose was removed, ready for an oak plug.
The inner stringer where the bullnose was removed, ready for an oak plug.
A bullnose glued and clamped onto the front edge of an oak tread in the shop.
A bullnose glued and clamped onto the front edge of an oak tread in the shop.
One of the wider lower treads next to its paper pattern — these were all different shapes.
One of the wider lower treads next to its paper pattern — these were all different shapes.
A tread glued up with Festool Domino joints and clamped across the bench.
A tread glued up with Festool Domino joints and clamped across the bench.
Curved treads at various stages lined up on the tool chest, some bare and some already stained.
Curved treads at various stages lined up on the tool chest, some bare and some already stained.
Close-up of a sanded tread showing the bullnose profile on the front edge.
Close-up of a sanded tread showing the bullnose profile on the front edge.
Stained risers and treads laid out on sawhorses and sticks to dry in the garage.
Stained risers and treads laid out on sawhorses and sticks to dry in the garage.
Curved treads spread across the living room floor during staining.
Curved treads spread across the living room floor during staining.
The Mapei Ultrabond ECO 977 adhesive used to set the risers and treads.
The Mapei Ultrabond ECO 977 adhesive used to set the risers and treads.
Test fitting finished treads partway up, with carpet still in place above.
Test fitting finished treads partway up, with carpet still in place above.

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