I am making new hand rails for some open stairs (no walls on the sides of the stairwell). the hand rail is about 40 degrees from the floor to follow the slope of the stairs. At the bottom and top of the rail I would like to have the hand rail end with a horizontal extension. The hand rail will be made from maple, about 2 1/2″ wide and 1″ thick (and yes I know this would not comply with the building code but it’s close). So my question is whats the best way to join the horizontal piece at each end to the handrail? The angle of the joint would be about 130 degrees. I do not think a simple glued miter joint would be strong enough. I would like to use some kind finger or box joint but cutting those fingers on the end of a 13 ft. long rail on a table saw or router table would be impossible. Can some kind of jig be made so I could use a router by hand?
Thanks
Brad
Replies
I would strengthen the miter with a loose tenon or even double biscuits. Cut the miters to the required angles and then cut your mortises or biscuit slots indexing off the face of the miter cut. If you’re routing for a loose tenon or spline, make up a mortising template for use with a template guide and straight bit. This template can fit right over the end of either piece of the railing, no matter the length. Clamp it on and rout to depth. Just be careful not to rout too deply. I have examples of these mortising templates in both of my books for Taunton.
Good luck, Gary
Gary
Thanks, I just ordered one of your joinery books. I guess I will need to make up some kind of jig to clamp it together, is that covered in the book?
I just recently joined and have read some of the questions and answers and they seem to be very helpful and informative, I'm glad I joined. And take it easy on those architects, some of us do our homework before we design and build stuff, but I know exactly where you guys are coming from.
Thanks again
Brad Rossi, AIA, NCARB
Brad,
Don’t get me wrong. I prefer architects. Architects are generally interested in doing things right and! they can be taught. Now interior designers, well don’t get me started on them. As for the mortising template, you’ll find them in either book. It’s basically a platform/ plate attached to a fence. You rest the router on the plate and clamp the fence to your work. Plunge rout with a straight bit and template guide. It’s pretty simple. You will have to have a vacuum nearby to clear out the chips usually, but it’s pretty quick stuff. Good luck and keep designing things for the world to see in 100 years. Best, Gary
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