This video documents the challenging and creative process of building a custom staircase for a cabin renovation. Faced with the discovery that the original 1976 home never passed inspection, the creator had to bring everything up to modern building codes. To circumvent design restrictions imposed by the code—such as the need for three stringers and riser toe-kicks which would obstruct the desired open look—he first built a temporary, ugly, but fully code-compliant staircase solely to pass the final inspection. After successfully passing, he demolished the temporary stairs and began fabricating the final version. This involved creating precise plywood templates, working with massive 13-foot solid oak boards in a small shop, and developing a unique design that uses thick apron boards as structural stringers. The video details the entire fabrication process, from creating a custom Rubio Monocoat finish to the near-disastrous moment the 500lb staircase almost collapsed. The project culminates in a complex, multi-person late-night installation, resulting in a minimalist, aesthetically-driven staircase that intentionally deviates from code for the sake of design.
The Three-Staircase Saga: Building Custom Oak Stairs for the Cabin
0:00:17 The Problem: The original 1976 staircase was ugly and not up to code. A county notification revealed the entire house was never officially inspected, meaning nothing was "grandfathered in" and all new work had to meet modern building codes.
01:34 The "Fake" Staircase: To pass inspection while preserving his desired design, the creator built a temporary staircase strictly to code. This included three stringers, riser toe-kicks to close gaps, and a bulky railing.
03:26 Passing Inspection & Demolition: The temporary staircase, which cost about $500, successfully passed the final inspection. It was immediately torn out to make way for the real staircase.
04:32 The Permanent Design Begins: Using scrap plywood, the creator built a full-size template at the cabin to ensure a perfect fit. This template would be used to fabricate the final stairs back at his main workshop.
09:56 A New Design Idea: Instead of traditional stringers with treads on top, the creator decided to use two thick, solid Oregon White Oak apron boards and attach the treads directly to them for a cleaner, more minimalist look.
11:02 Fabrication Challenges: The 13-foot-long, heavy oak boards proved difficult to maneuver and cut in the creator's small workshop, requiring him to open multiple doors and re-orient his table saw just to make a rip cut.
20:01 Precision Assembly: Domino joiners were used for precise alignment of the treads, and long structural screws (dipped in paste wax) were used to securely fasten the treads to the apron boards.
25:02 Custom "Pure Nut" Finish: To perfectly match the existing flooring, a custom finish was created by mixing Rubio Monocoat "Pure" and "Walnut" in a 50/50 ratio.
31:17 Near Disaster: While standing on its side in the workshop, the massive, nearly-assembled 500lb staircase became unstable and almost fell over, requiring an emergency call to a neighbor to help save it.
34:11 The Complex Installation: Installing the finished staircase was a multi-person, late-night effort. It involved using a temporary 2x4 ledge for support, safety straps, and crawling under the house to secure the base of the stairs to the floor joists.
39:49 Final Aesthetic Tweak: After installation, a last-minute decision was made to paint the upper oak support piece white to better blend in with the white beam it was attached to.
40:36 The Finished Product: The final staircase is simple, clean, and maintains the open feel of the entryway. The creator plans to add a wall-mounted handrail but will leave the open side without a railing, acknowledging it is not up to code but prioritizing his aesthetic vision.