Azek buildups

[mahogany]

I would like to build some azek columns simliar to the ones in the photo. I have thought about buying them premade out of fiberglass or azek but the cost is upwards of 600$. My question is what's the best way to fabricate it so they don't blow out with changing weather. Also what is the best joint for the outside corners. When you laminate several pieces together like a rail and frame on top of a 1/2" sheet, will they all move together? These will be painted white.

thanks

[dlhunter]

Have you figured out how much it will cost to buy the material to build them yourself? By the time you buy the materials and put the time in to build them properly you might not be saving all that much. Last time I bought 4x8 sheets I think I paid $90 for 1/2" and $120 for 3/4.
I built some colum pedestals a while back. Instead of cutting rails and stiles I cut a rectangle out of a sheet of 3/4" then cut a rectangle out of the middle so instead of 4 separate pieces it was one. 4 less joints to worry about. Then routered a profile on the inside and backed the frame with 1/2" sheet.
I mitered the corners and used a lot of glue. A lock miter would be better and that's what I would do now. The two piece premade Collums they sell now come with lock mitered corners.

[Brice Burrell]

I've done similar build ups to what you're trying to do numerous times with good success. I'd agree with dlhunter about looking carefully at the costs involved with making these yourself. If you do decide to make them yourself, pocket screw the frame and insert the molding. Be sure to glue everything so it will all hold together and move as one. I'd skip the mitered outside corners and just butt joint them. I think that gives you a better joint outside and saves a ton of time.

[Kent Brobeck]

Do they sell columns that are built like that? I give a disclaimer...I'm not a big fan of Azek. That said I frame and panel post like that could be done with a lap joint. Set up 2 routers with rabbiting bits. The initial set up is a bit fussy but one you have it your good. With the lap joint you want to leave one side just a bit proud and then flush it with a flush trim bit after installing with PVC glue and clamps.

The frame and panel could be built with a cope and stick bit using 1/4" Azek for the panels. That way the panels could be independent
of the frame. One thing about Azek is that it is really flimsy. You need a very solid backer behind it or forget about it.

I'm guessing the way those columns are built there must be some kind of base detail. Wondering why there is a little panel at the bottom of the post if I'm seeing it clearly.

[Kent Brobeck]

Do they sell columns that are built like that? I give a disclaimer...I'm not a big fan of Azek. That said I frame and panel post like that could be done with a lap joint. Set up 2 routers with rabbiting bits. The initial set up is a bit fussy but one you have it your good. With the lap joint you want to leave one side just a bit proud and then flush it with a flush trim bit after installing with PVC glue and clamps.

The frame and panel could be built with a cope and stick bit using 1/4" Azek for the panels. That way the panels could be independent
of the frame. One thing about Azek is that it is really flimsy. You need a very solid backer behind it or forget about it.

I'm guessing the way those columns are built there must be some kind of base detail. Wondering why there is a little panel at the bottom of the post if I'm seeing it clearly.

[dlhunter]

If you look even closer it looks like there is a even smaller exposed panel at the top. An inch or less. Maybe they came as 12' posts and were cut down.

[mahogany]

the post that you see are made of wood and not trimed out yet. They lasted about five years. Thanks for all the replies it gives me something to think about. This is for personal use, otherwise I would have no problem with purchasing them. also i am just curious becuase sometime I need to make multilayered ext. millwork and I am looking for an alternative to wood.

[Loren97]

Versatex (a competitor of Azek) make some very nice column wraps. You could get a 6x6 column wrap and do what dlhunter suggests with cutting out a rectangle and routing it out, backed with 1/2 material on the inside and still be able to slip a 4x4 up through the middle. The Versa-wraps (http://www.versatex.com/versawrap.php) come flat with a glue miter corner on three sides and a lock miter on the last side. You glue all the joints and they are pre-taped so you just wrap it around your post and press the lock-miter together and presto-- a perfect column. A 6x6x8 wrap is probably around $120-150ish. They are only about 3/8" - 7/16" thick if I remember right, but enough to give some profile...

[Brice Burrell]

Versatex (a competitor of Azek) make some very nice column wraps. You could get a 6x6 column wrap and do what dlhunter suggests with cutting out a rectangle and routing it out, backed with 1/2 material on the inside and still be able to slip a 4x4 up through the middle. The Versa-wraps (http://www.versatex.com/versawrap.php) come flat with a glue miter corner on three sides and a lock miter on the last side. You glue all the joints and they are pre-taped so you just wrap it around your post and press the lock-miter together and presto-- a perfect column. A 6x6x8 wrap is probably around $120-150ish. They are only about 3/8" - 7/16" thick if I remember right, but enough to give some profile...

I never saw these before and they seem like a might be a good alternative for some situations. Thanks for posting.

[copperhead]

While I didn't care for the overall design, here's a job using Azek to the extreme.

Everything in the picture that is white is Azek...The columns, all the parts of the railing, the trim, etc. The larger parts are built up over either LVL material or conventional framing material. There is even a steel beam encased in the Azek(which ended up not being needed when the design was changed). Some of the railing parts are just laminated stock, some of it has flat stainless steel stock sandwiched between the pieces. We screw, glue and butt joint most of the parts. Except for maybe the joints, everything is done pretty much the same way you'd "wrap" any other type of framing with wood. As mentioned though...the cost factor gets really crazy... in time and in materials. I stopped counting when the cost of just the screws used in this project exceeded 2500 dollars.

We use a lot of the stuff. Personally I don't enjoy working with it, but will admit is certain instances(especially near the water) it has its places. We always screw it, fill the holes with west system and paint it. Handling the material and trying to keep unblemished is next to impossible. Even when it can be accomplished and then plugged, IMO it has too plastic a look. If you really want to use it, and can find what you want pre-fabbed, I'd go that root. That high cost may be a better deal than you think.