To make the handrail joint shown in the drawing, I start by laying out and cutting the first piece, then using it as a pattern for the second piece. Next I temporarily clamp the two together and improve the fit by running a saber saw with a fine-toothed blade through the tight parts of the joint until I’m satisfied with the fit. For 2x6s, I use a 5/16-in. by 5-in. machine bolt (countersunk on both edges) to hold the pieces together. If I’m making more than one joint, I first make a pattern out of aluminum flashing or cardboard.
Les Watts, Hemdon, VA
