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handrail fittings WITHOUT CNC11/12
I'm milling about 135ft of a custom (stair) handrail today & tomorrow, and within the job, are several transitions (upeasings, level quarter turns, Bullnose ends, etc)
For this profile, I have matched (very large) Custom Router Bits
does anyone have any preferred methods for milling the fittings (without a CNC)
I have some interesting jigs & fixtures I've been using the past couple years, but of course I can't leave well enough alone, as there's always someone who knows a better trick for getting the job done!
milling flat rails, turns & bullnose rail ends are straienough, upeasings (especially when they're on the end of a 13ft rail blank!). are a resl challenge!
Any new ideas greatly appreciated!
I like to use the lathe for up and over easings. I have also used an over arm router with a swing jig, as well as a shaper with a swing jig.
your initial comment had one of my brows raised in a "now, does he understand what I'm talking about" ponder. -that it until it "hit me". Lathe? oh! I get it ! but wait a sec. thats a mighty big chunk 'o glue-up you're spinning (if I am understanding correctly).
but here are my issues with this particular job:
& while a 2-4ft straight rail projecting off an easement could help with the milling procedure, 13foot straight rail is nearly impossible to handle.
has anybody ever heard of a "French Spindle"?
while we're on this subject, has anyone ever milled an ascending volute or turnout; by conventional means (without CNC) and without literally hand-carving the part?
From a Google search:
I constructed a handrail milling machine years ago and it's still on the job although I will plan to lretire soon After more than 20 years now, I've managed to learn a few things although it's still a bit of a proprietary concern. I haven't turned any stair handrail parts on the lathe for 40 years now. I mill descending volutes and all kinds easings and any kind of curved handrail up to about 4"without CNC (see my profile). It hasn't been free though since cutters cost hundreds. I ruined a French spindle recently so I no longer f with that. I've also made myself a sort of expert on tangent handrail too since that was part of the package.
However you approach all this, please be careful as milling handrail fittings without CNC can be hazarded to your health.
The old French spindle shaper was particularly wicked .
Scmi R9 tilted head Can make damn near anything with massive cutters. Takes a big pair to run and will put some hair on em