Seeking Railing Fabrication Ideas
About two years ago we did 3 story curved stair project for a client in Manhattan.One of the options we explored at one point was a handrail design would look like the scanned image of a xerox below. We followed the idea for a while making a few straight section samples but due to time constraints on the whole project we ended up using another hand rail profile and design.
I thought I’d put this question up here since I now have another potential client who might be interested in a design like this for a curved stair only on a smaller scale (single story) and I like to get some feedback as wee figure out how to do this thing. I think I’ll also post this question over at Knots too since I think the techniques involved probably span both realms of expertise.
Click for a larger image
View Image
Back then we ( I ) fabricated a set of samples done as straight sections to work out the handrails size and whether the “ribs” would be beaded or a rope pattern. The problem(s) I discovered we would face are these: The straight section samples I hand carved and shaped the rope and bead patterns from ribs that I applied as glued on appliqué’s, that was easy (or easy enough). But this rail is a helical curve with a volute just like the scanned xerox above and that where the problems lie.
| View Image | Railing Profile Cross-section The railing material would be Genuine Mahogany (Honduran) The bead or rope pattern would be on the top two ribs while the bottom two would be solid (no carved pattern) |
How do you shape and fabricate and then detail a piece like that? Both the bead and rope pattern pose different problems regarding”how-to-do-it” and thereby different solutions so we leave it open to consider both possibilities.Even the plain rib on the bottom poses some real difficult problems when you try to shape the rib on a helical curved section.
So any ideas out there? Tools, equipment or materials?
Edited 5/30/2002 12:00:06 PM ET by Jerrald Hayes
Replies
Jerrald--
Sounds like an interesting, fun project. It sounds as if fabricating a curved railing is already within your bag of tricks, so I won't go into the techniques of bending the actual rail.
To simplify fabrication, could you start with a readily available "bending rail" such as from Leeper's, LJ Smith, or another stair part manufacturer? If you chose an oversized rail profile (like a 6701 from LJ Smith @ 2-3/4"W x 2-1/8"H) you would be able to locate your top and bottom beads on one of the laminations--giving you the ability to carve the bead and bullet or rope detailing on one flat, rectilinear piece. You could modify the profile by re-cutting each of the laminations to fit. What I like about using the bending rail is the "keyway" that keeps the profiles aligned.
I suppose you could get the same results by making your own keyed laminations, if you so desire.
I hope this gives you an idea, even if it isn't what you end up using.
Have fun--be sure to post pictures of this beast!
Syd
Syd-I just saw a example of one of the of the reasons we avoid or don't like
the using bending rail. Check out Mahogany
gap filler over in Knots. Maybe too you might have an idea to contribute
there. I also just saw your Steam
Bending topic over there too. How did that work out? I'll post over there
some of what I've learned from my experiences ( and failures) with steam bending
rather than posting them here to maintain some kind of contextual continuity
with these forums
"Do not go where the path may lead, go
instead where there is no path and
leave a trail."-- Ralph Waldo Emerson