Here are the basics of what you need to know about stair handrails before attempting this DIY project. Building your own wooden stair handrails can be a challenging and rewarding process. Before you try to tackle this project, it is important that you understand stair handrail terminology.
Main Parts
The rails are the horizontal pieces into which the balusters fit. The top rail is the handrail, and the bottom rail is the shoe rail. Each rail is plowed out along its length, leaving a space in which to fit the balusters.
The balusters (or spindles) are the vertical pieces that fit into the hand and shoe rails. They come in two sizes: 1 1/4 inch and 1 3/4 inch, and two styles: square or turned. Turned rails have been spun on a lathe to create different designs, however, their tops and bottoms are kept square so they fit into the plowed out areas of the rails.
Fillets are strips of wood, which fill in the plowed areas of the rails, holding the balusters snugly in place, keeping them evenly spaced, and giving a finished look to the rail. They are a convenient option to drilling holes for the balusters, and come in a variety of profiles.
Newel Posts
Newel posts come in a large variety of shapes and sizes, and you should select your newel posts with location in mind. They can be square or turned, plain or fancy, and come in many different styles. One example of a newel post would be a square post with an acorn top. Some styles of newel posts require some extra mounting plates for proper installation.
Other Parts
There are other parts that may be necessary, depending on the style of handrail that you decide to install.
Rosettes are optional wooden pieces that fit between the handrail and the wall. They add a decorative touch, or you can omit them for a clean and simple look.
Cap boards cover the knee wall that the railing may be built on.
Bull nose is an optional covering for either a floor edge or a stair edge where the railing overlooks a landing or a room.
Consistency
It is important that when you select and order parts to build your handrail, you choose parts that work and fit together, and that the top and bottom rail match. Once you have decided which size of baluster to use, you must consistently choose that size for the balusters, the plowed out area in the rails, and the fillets, or they will not fit together.
Safety
OSHA has set height requirements for the safe construction of handrails, and it is important to meet these requirements when working on your project.
Building your own wooden stair handrail is a basic, satisfying project that can be modified in many different ways to fit your style and budget.