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 also posted this over on BreakTime since I think the techniques involved probably span both realms of expertise.
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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?
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“Do not go where the path may lead, go instead where there is no path and leave a trail.”– Ralph Waldo Emerson
Replies
I've not done much myself in this line, but many moons ago I worked in a workshop where they had one employee who did all the handrail work that came in. He mostly worked in solid timber and shaped moulded and carved what was needed after working out patterns etc.. If you have time to order the book and wait while it's sent to you, George Ellis in Modern Practical Joinery describes traditional stair handrail work in some detail. ISBN-- 0-85442-039-8. I'm pretty sure the online booksellers sell it. It sounds like you have a good idea of what you need to do, but if you're lacking confidence, Lee Grindinger who sometimes drops in here is a fine carver, and might be amenable to some sub-contract work. Just a thought. Slainte, RJ.
Interesting parallel RJ, we ( mostly I) do all all the railing work for a local
Ironwork shop here in NY. I went down there just after I originally posted my
message here and one of the guys there asked what I as working on now and I
showed them the picture and they started to laugh. They all know I'm not afraid
to try anything so they're always asking what I'm up too.
Yeah I do have a pretty good idea of what something like this takes but that
doesn't mean I've figured out everything. When we're working on something new
and different I ask questions of everyone, novice to master. I'll ask an 18
ironworker woodworking questions ( I just did). Often in the past I've discovered
that some of the best ideas come from people who have no idea at all about what
you doing. The trouble with experience is our decision making is often tainted
by how we have done things in the past so we aren't working with a wide-open
clean slate and our creativity can get stale. So I ask questions all the time.
Period. I call it "getting stupid" or see it as adopting "Zen
Mind, Beginners Mind". Seems to be working and we get some pretty neat
projects thanks to that attitude.
Like the fellow you just mentioned the work we do is done in solid or built
up material too. We don't do any bending rail (using keyed laminations) that
fellow here with the Mahogany
gap filler problem is just one of the reasons why. Reading the book Modern
Practical Joinery is one of the reasons I am both interested and able to
tackle stuff like this so that's a great recommendation for anybody. Thanks
so far.
"Do not go where the path may lead, go
instead where there is no path and
leave a trail."-- Ralph Waldo Emerson
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