I've been limited to working on this project on weekends only, so it seems to be taking me a lot longer to finish this one. There were actually 2 layers of treads and risers on this staircase, which really screwed up the rise for the first and last step. Apparently a flooring guy just cut the nosings off the existing treads, then set the new treads and risers in a bed of liquid nails and sunk about 20 18 ga. brads into each tread, then used excessive amounts of molding to cover the gaps.
The homeowner wasn't crazy about the excessive use of molding on her existing staircase, so for this project I routed dadoes into the underside of the treads to receive the risers for a nice clean look. The outside treads needed a stop dado, which I made on my Festool toys. I also picked up a Wheaton tread template jig so that I could get a perfect fit for each tread and riser. The starter step was also a lot of fun to make. I made a series of relief cuts on my table saw to the back side of the riser so that only 3/32 of material was left, then I wrapped and clamped it around a 2x form slathered in polyurethane adhesive.
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cont'd...