In
This Article:
The stair nose angle is
determined and the wood posts are cut to length. The sections
of handrail are assembled. Top mounting brackets are modified
but the bottom brackets have to re-invented. Much agony ensues
as sections of railing are installed. |
Related
Articles:
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Skill Level:
4+ (Advanced) |
Time Taken:
About 8 Hours |
By
Bruce W. Maki,
Editor
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The stairs before the handrails were
installed.
These two treated 4x4 posts are 8 feet long, and go
about 2½ feet into the ground. I purposely used
extra-long posts here, knowing that any post for a stair
handrail will likely be a bit longer than ordinary posts
for "flat" or horizontal handrails.
Click here
to read about building the stairs and the
installation of the posts shown above.
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The posts for the flat handrails (the long horizontal
railings along the edge of the deck) are all 8-foot 4x4's cut in
half and bolted to the rim joist of the deck frame. Those posts all
stood about 40 inches above the finished deck surface. Click
here to see the installation of those posts.
Determining the "nose angle":
- The "nose angle" is the the angle above
horizontal of the "nose line".
- The "nose line" is the imaginary line that connects
all of the overhanging points of the stair treads.
- The nose line can be obtained by laying a straightedge across
the stairs, like the level in this picture.
I laid a 2-foot level across the stair
edges and marked a line on the post. |
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I used a speed-square to measure the angle
of the line. The red arrow points to the angle mark.
I measured 34 degrees above horizontal.
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Tips On Measuring Angles:
If you are even slightly confused about why
the angle is measure on the vertical edge, I
don't blame you. I have an engineering degree, most of a
math degree, and a decade of experience working with
carpentry, and sometimes I still get turned
around when measuring angles.
Here's how I visualize it... It's kinda goofy:
Imagine the picture above, but the speed-square is
rotated until the left-hand edge is all the way against
the post. I align the pivot heel at the point
where the red line meets the left edge of the
post (i.e. the red line seen in the picture below).
That's my starting point. (I know... I should take a
picture to explain this...)
When the speed-square is in this starting position,
the vertical edge of the post is aligned with the zero
degree mark. That means that the bottom edge of the
triangle is zero degrees above horizontal.
Now I rotate the speed-square, keeping the pivot heel
against the end of that red line. I imagine the lower
edge of the speed square is a cannon, and I'm
ordering the gunner to raise the cannon skyward. As the
gunner tilts the speed-square counter-clockwise, I call
out the angle that the "cannon" has reached,
because I'm looking at the marks that align with the left
edge of the post. When the lower edge finally aligns
perfectly with the red line, the gunner stops and I read
the angle, in this case 34 degrees.
That means that my red line is 34 degrees above
horizontal. The line is also 56 degrees from vertical,
because 90 degrees (a right angle) minus 34 degrees is
56 degrees. It is REALLY EASY to get a wrong
measurement if you hold the speed-square the wrong way.
That's why I go through the whole cannon-elevation
silliness, I can see the rotation of the
"cannon" as it goes from horizontal (if that's
the reference "line" that I want) up to the
line that I've drawn.
One of these days I'll write an entire article about
tips and techniques for measuring angles.
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I drew a line along the bottom of
the level (blue line). This is the "nose
line".
Then I made a mark one inch higher than the
nose line. This will be the bottom of the handrail. The
bottom of my handrail should be one inch above the nose
of the stair steps. |
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King-Sized Mistakes:
Monarch's instructions say "Make sure the
minimum spacing allowed by local code (4") from the
nose of the stair tread to the bottom of the rail is
maintained." Yes, their instructions say minimum...
but you should know that the building codes are
concerned with MAXIMUM openings around handrails.
Unless the codes have been
totally revised, the requirement is that the
triangle-shaped area below a stair handrail shall not
allow a ball or sphere to pass through that is greater
than 6 inches in diameter.
The space between balusters or under a railing
cannot pass a ball or sphere that is greater than 4
inches in diameter. This rule would be very difficult to
maintain for the triangular opening below a stair
handrail, so the codes make an exception.
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The flat handrails are about 32½ inches
tall (not including the gap below the bottom rail).
I marked 32½ inches above the previous mark, to
indicate the top of the handrail. |
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Then I marked a point 4½" higher.
This will be the top of the plastic post sleeve.
This mark is 42½" above the step, but this
dimension could be different for other handrail
situations.
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To double-check my layout, I placed a
4-foot level on the layout mark for the top edge of the
handrail, just to see where the top cap would intersect
the end post.
This should work fine. |
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I cut the 4x4 posts with a circular saw,
which requires two cuts because the blade can only cut
about 2½" deep.
Actually, I cut these posts about ½" higher
than the mark shown two photos back, because the post
cap needs that much wood protruding beyond the sleeve.
Alternatively, I could have cut the sleeve a half-inch
shorter.
Then I slipped the sleeves over the posts.
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Cutting The Retainer And Bottom Rail:
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Without thinking about the consequences, I
began by cutting a 34 degree angle on the upper ends of
the retainer and bottom rails.
Then I realized I missed something... |
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... the alignment of the holes.
With conventional wood handrails, I would simply cut the top and
bottom rails to the desired length, then go about installing the
balusters at the proper spacing. But these holes are already
drilled... and not once did I think about the hole layout
when I chopped the ends off the first pieces of rail.
I looked at my first retainer and bottom rail and realized that
the the hole-to-end distance was not the same at the lower end as
the upper end. But they were within an inch.
If I wanted those dimensions to match (which they should) I would
not have enough bottom rail stock or retainer stock. I would need to
open the extra box of railing (which the homeowner planned on
returning for a refund) which would cost quite a few bucks.
The retainers and bottom rails. |
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It's important that the distance from the
top end to the center of the first hole be the same on
the bottom rail... |
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... as the retainer.
It's also good to have this dimension equal to the
last-hole-to-bottom-end distance.
I didn't have such luck, and I didn't have the
patience to figure it out. |
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On the bottom rail, I re-drilled the
holes at the 34 degree angle required. I cut a piece
of wood at the same 34 degree angle and clamped it to
the bottom rail. This piece of wood acted as a guide to
help me maintain the proper angle. This required an
extra-long 3/16" drill bit.
Note that the retainer (which is part of the top
rail) did not need to have the holes re-drilled at an
angle. That's because the retainer is quite thin, while
the bottom rail is about 1½" thick.
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I cut each baluster at the 34 degree
angle, being careful that the ends were parallel to each
other, and all the balusters were the same length. |
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I screwed the balusters to the retainer.
The screws need to be tightened carefully so the top of
the baluster gets fully seated, yet the screw does not
strip out the plastic. |
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To attach the bottom rail, I first started
a screw in each baluster, otherwise it's
impossible to see the center hole in all but the first
baluster. |
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Note the screw head. The original hole is
about an inch to the left. |
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I put the assembled handrail into place to
test the fit.
The L-brackets provided won't work for angled
railings. Monarch's instructions mention some
special-order brackets for stair railings, but I wasn't
willing to wait up to a week to get them.
And there was another problem. I was planning to use
one handrail section for two short angled stair rail
sections. But I needed 8 mounting brackets, and I only
had 4.
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Not only did I need to bend the original brackets to fit the
angled railing, but I needed 4 more brackets in a hurry.
I decided on a two-pronged approach: Customize the original
brackets for the top rail mounting brackets, and fabricate my own
bracket to secure the bottom rail.
Top Rail: Customizing The Brackets:
The brackets supplied with the Monarch handrail needed to be
modified for the stair rails. One had to be made tighter
(more acute, less than 90 degrees) and the other had to be made broader
(more obtuse, greater than 90 degrees).
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For the acute angle, I cut a scrap
of wood to the 34 degree angle of the stair handrails.
Then I clamped the metal bracket between the block
and a workbench. |
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I smacked the bracket with a hammer.
Actually, I initially used a block of wood as a
buffer, placing the wood against the metal and beating
on the wood. As I got close to the desired angle I
didn't use the wood. |
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For the obtuse-angled bracket, I
simply placed the piece of metal on a block of wood and
hammered on the corner. Since the metal is narrowest at
the corner, it bent there with only slight bending
elsewhere. |
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I checked the bracket against the 34
degree angle cut to verify that I had the correct shape.
This was pretty easy... it only took a minute or two. |
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Bottom Rail: Saved By The Hangman:
When I tested the fit of the first stair rail section, I realized
there were going to be some problems with attaching the bottom rail
to the posts.
If the mounting brackets were attached to post first, it would be
impossible to drive a screw into the underside of the retainer.
But if the brackets were installed on the underside of the bottom
rail first, then it would be impossible to drive lag screws into
post.
I thought that maybe the only approach would be to pre-drill and
pre-install all fasteners, including the lag screws that hold the
brackets to the post, then remove those lag screws and attach the
brackets to railing. Then I would have to install the lags with
wrench. I had enough room for a box-end wrench.
BUT... that sounded like a pain in the @$$.
My solution came while browsing the hardware aisle at the spankin'
new Menard's store nearby. I envisioned using the Hangman
Products model HP6 aluminum picture/mirror mounting hardware to
fabricate brackets to support the lower rail. This hardware is
essentially a pair of ramps that keep a picture on the wall, and I
thought that I could use them to at least keep the bottom rails from
moving sideways or downward. The upper mounting brackets will
prevent the railing from moving upward
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The Hangman model HP6 contains two 6"
long aluminum strips, a plastic level vial (which I
won't need) and mounting screws. This package costs
$4.98 at Menard's. I bought three packages, although I
only needed two. |
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Using a small scrap of the bottom rail, I
made this test piece to see if my idea would work. |
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I mounted the test piece to the wall of my
workshop. It worked. |
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To make this test piece, I placed a scrap
of bottom rail in a vise and marked the location of the
pocket that I needed to rout. |
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I used a Rotozip with a ¼" collet
and a ¼" straight-flute router bit.
I adjusted the depth of cut to ¼ inch. |
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I carefully routed the pocket,
being cautious to avoid cutting through the outside wall
of the pocket.
This is very tricky because the base (or
"foot") of the Rotozip tool is so big that
there is very little base to rest against the piece
being cut. I had to be super-alert to always keep some
part of the base in contact with the handrail end. |
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It seems to me that there would be a market for a replacement
base for the Rotozip, one with a much smaller opening. The base
can be easily removed and replaced. If somebody made such a base,
I'd buy one.
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It's kinda hard to see, but
there is a one-quarter inch deep pocket milled into the
end of this piece of Monarch bottom rail. |
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I cut a piece of Hangman with a hack saw
and a vise. This piece was just shy of 1-3/8" long. |
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I used a small bench sander to smooth down
the burrs made from cutting the aluminum. This could also be done with a file.
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I drilled two mounting holes in each
piece. |
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After drilling each hole, there was a burr
on the exit side of the hole. I took a moment to sand
down this burr before drilling the next hole, because
the burr prevented the part from sitting flat on the
drill press table. |
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Of course, a regular hand-held drill works just as well.
I mounted the aluminum clip to the pocket
of the bottom rail.
I used a #6 Vix bit to pre-drill the pilot holes, and
#6 x ½" stainless steel sheet metal screws to
attach the aluminum clip. |
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At the job site, I routed the pockets in
the ends of the bottom rails. |
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I attached the aluminum clips.
On the upper ends, the original two screws almost
poked through (into the inner void). Not wanting these
screws to pull out, I added a third screw at a lower
position where there was more material to bite into. |
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Handrail Section Installation Process:
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First I tested the fit of each handrail
section. There's no point in fighting with a section of
railing that is too tight or too loose. |
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Upstairs End, Top Rail:
I used flat-head screws here and I tilted the
drill so it was parallel to the balusters. |
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I used a flat-head screw with a washer.
Washers are absolutely necessary because the
holes in the brackets are too big for the fasteners that
Monarch provides. |
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Downstairs End, Top Rail:
At this end I also angled the drill so it would be
parallel with the balusters. |
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I used two flat-head screws (about
3/4" long) with #10 washers. |
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I set the railing in place again, resting
on a scrap of decking, which is one inch thick. This
will give the railing a good height above the stair
treads. |
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I marked the locations of the holes in the
brackets so I could pre-drill the mounting holes in the
posts. |
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I removed the railing again, then I
removed the brackets from the top rail.
I placed the bracket against the post and pre-drilled
the holes and drove in the lag screws. Note how the
upper lag screw was angled. |
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This is kinda piss-poor... but my patience
is wearing thin.
I could have just drilled on the pencil marks,
without using the brackets as a guide. That would have
allowed me to drive both lag screws in straight...
although I would've had to use a wrench for the top lag.
This bracket should be made about an inch taller.
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The other bracket (the obtuse one) was
easy because there's nothing to get in the way. |
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I put the handrail back in place and I set
the custom-clips into position. This was kinda sketchy
because I could not be sure the clip was making full
contact with the corresponding clip on the bottom rail.
I secured the clip temporarily with duct tape.
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Then I removed the railing again.
For the upper post it was easy to secure the clip
with 1" long stainless steel sheet metal screws. |
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The clip for the bottom end proved to be a
conundrum. There was only about 2 inches between the
post and the step. There was no way I could get any
tools into that tiny space to drill a hole or drive a
screw.
Then I realized that I could just remove the post
sleeve. I pre-drilled the holes using a Vix bit. |
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Then I used a couple of short #6 screws to
hold the clip in place. I drove the screws tight, then
I backed them out part way, because the screw points
would prevent the sleeve from being slipped back onto
the 4x4 post. |
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I replaced the sleeve on the wood post... |
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...and I used an offset
screwdriver to tighten the screws. |
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I slipped the handrail into place AGAIN. |
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I installed screws into the top rail any
way I could. Even though I had pre-drilled the holes and
already driven screws here, I was not able to replace
the screws in the original holes. This was caused by the
4x4 deck posts being twisted and knocking my angle
brackets out of alignment. |
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Screws installed at the upper connection.
This end was also difficult, because the screws would
tilt at an angle and I couldn't keep the drill/driver
aligned with the screw, so the head would strip. |
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In spite of my careful layout work, the
top connection managed to shift to an off-centered
position. I think this may have been caused by the
sloppy fit the mounting brackets have on the retainer. |
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Finished handrail. It looks nice,
especially from a distance. |
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Afterwards I applied a bead of white silicone caulk to the
gaps between the handrail and the post. This caulking seemed to do a
good job of making all the components blend together.
The completed project... after the
skirting had been installed around the outside of the
deck.
They were a royal pain in the neck to install,
but they look good now.
If I was asked to do another set of stair handrails
with Monarch synthetic railing, I would charge at least
8 hours of labor for one pair, regardless of size. This
should be a 2 or 3 hour job, but Monarch's design makes
it difficult. |
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Tools
Used:
- Cordless Drill/Driver
- Cordless Impact Driver
(Optional)
- Basic Carpentry Tools
- Extra-Long 3/16"
Drill Bit
- Miter Saw
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Materials Used:
- Monarch Synthetic
Handrail, 6' x 36"
- Hangman® Model HP6
Picture Hanging Hardware
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