Crafting a Masterpiece: A Florida Staircase Inspired by Sotterley

I’ve always loved creating unique pieces, but one of my greatest joys is teaching others something new. That’s exactly what happened when my former Program Manager approached me with an ambitious request.

"Chris, I have a house in Florida, and I want you to make my staircase."

He envisioned a staircase inspired by the historic Sotterley Plantation in Southern Maryland. After visiting the site to study the intricate design, I immediately thought, "This is going to require a lot of cutting."

When he asked, "Is it doable?" my response was simple:
"Yes... and you’re going to build it."

To this day, I’m not sure if the look on his face was excitement or fear, but by the end of the project, one thing was certain—he was hooked. He had experienced firsthand how rewarding it is to create something from nothing.

The Scope of the Challenge

To put this project into perspective:

• 500 individual parts were handcrafted
  
  

• 4,000 passes on the table saw (not counting raw material prep)
  
  

• 3,000 strokes on the mortise jig using a drill press
  
  

• 2,000 cuts on the bandsaw
  
  

• One full summer’s worth of weekends to complete
  
  

This wasn’t just a staircase; it was an manufacturing feat. Four custom jigs were designed and built to ensure precision, and through careful craftsmanship, all parts were within 0.020” tolerance—a level of precision even some machine shops struggle to achieve.

The assembly process was meticulous. We first constructed individual "H" frames, then connected them into full panels, each measuring up to 10 feet. Amazingly, when everything came together, the design squared itself up—exactly as planned. Whew!

The Finishing Touches

The handrails were relatively straightforward—until we decided to include goosenecks. For the level of detail this project deserved, I designed a 3D model and toolpaths for the ShopBot CNC to mill the curves with near perfection, requiring only minor sanding.

Straight sections of the handrail required custom shaper cutters, ground to order, and then milled on the shaper. Hollow newel posts were designed and built for added strength and aesthetic.

Finally, all components were carefully packed into custom shipping containers and sent off for installation in Florida.

An Unexpected Bonus Project

As an afterthought, we looked at the remaining walnut and extra parts that had been produced to account for scrap loss—but weren’t needed thanks to the precision of our work. Instead of letting them go to waste, we decided to create something special: a custom table.

Using cabriole legs, a glass top, and sections of the "H" frames, we designed a table that fit perfectly into the corner of the staircase. This unexpected project was the perfect way to repurpose the leftover materials and create a one-of-a-kind piece to complement the grand staircase.

Looking back, it was an absolute pleasure to design and build this staircase. Knowing that years later, these steps and railings still stand strong in his home brings a deep sense of satisfaction