How to fit Fusion Mk1 Spindles on Stairs

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How to fit Fusion Mk1 Spindles on Stairs

	How to fit Fusion Mk1 spindles on stairs

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	Contents
	Step 1 - Measure your stairs Step 2 - Measure handrail height Step 3 - Check spindles Step 4 - Assemble the MK1 spindles Step 5 - Mark & cut baserail to size Step 6 - Position baserail Step 7 - Attach connectors Step 8 - Position handrail Step 9 - Cut handrail to length Step 10 - Attach top connector Step 11 - Secure handrail		Step 12 - Measure & mark spindle positions Step 13 - Using tape measure Step 14 - Mark hole positions Step 15 - Drill pilot holes Step16 - Drill baserail fixing holes Step 17 - Fix spindles to baserail Step 18 - Check spindle alignment Step 19 - Fix first spindle to handrail Step 20 - Fix remaining spindles to handrail Step 21 - Repeat Step 22 - After care

measure your stairs, Fusion MK1 spindles, MK1 spindles, staircases, landings, Fusion, baserails, handrails, newel posts, newel caps, WONKEE DONKEE says: Measure along what we call the string, the tape needs to be kept at the same angle as the stairs to beaccurate.By the way, did you know that the end of your tape measure is loose for a reason? Click here, or on me, for more info., diagram, newel post, fusion newel post, newel base, string, how to measure stairs

Step 1 - Measure your stairs

Measure the distance between the inside faces of the newel posts (ND).
Measure the width of the newel base (w). Enter these two dimensions into the Wonkee Donkee calculator. This will give you the number of spindles that you will need, as well as the spindle centre positions. (The height of the handrail is determined by the spindles as shown later).

Fusion TM components, MK1, Fusion, measure stair pitch, WONKEE DONKEE says: Align the protractor on the newel post or the floor whichever is the most level. If you need more help, follow the link below, or click on me!

Step 2 – Measure stair pitch

Measure the pitch of your staircase.
You may use the printable protractor to do this.
There are other methods of measuring your stair pitch - including measuring tools and also “Apps” for your phone/tablet that can be used.

Marking landing newels, Fusion, MK1 Fusion, stair Fusion, newel posts, WONKEE DONKEE says:

Step 3 - Check spindles

If you are using the MK1 type spindle, you will need to assemble them before going any further. The MK2 type spindle needs no assembly.

Newel trim instructions, trim newels to height, how to trim newels, stairs, newels, richard burbridge, Fusion, WONKEE DONKEE says: "When tightening the screw, be careful not to over-tighten or you may strip the thread and then you will not be able to tighten the screw properly. Best way is to screw down until the head makes contact with the material (you will feel the resistance) and then tighten a further half turn."

Step 4 - Assemble the MK1 spindles

Insert the brackets into the spindle tubes as shown, and secure with the supplied 63mm long screw.
Ensure that the brackets line up with each other by placing on top of two blocks of wood before tightening.

We suggest that you leave one of the brackets unassembled - this will be used later to mark the hole positions on the baserail without scratching the spindle's finish.

Tape measure instructions, mark baserail vertically along the newel post, marking baserail, cutting baserail, sizing baserail, richard burbridge, stairs, Fusion, MK1lic Fusion, MK1 Fusion, MK1 newels, fitting MK1 spindles, WONKEE DONKEE says:Make sure that the ends are cut clean and square since this final cut will be in full view.

Step 5 - Mark & cut baserail to size

Place the baserail on the stairs so that it runs parallel to the string. Make a vertical mark on the side of the baserail at both ends where it meets the newel bases. Using a handsaw, cut the baserail to length.

How to mark bottom newel, richard burbridge, fitting MK1 newels, marking out lines, cut point, baserail offcut, stairs, staircases, richard burbridge Fusion, WONKEE DONKEE says: The baserail is not fixed down at this stage because you don't want to see the fixing screws. Wait ‘till you know where the brackets will be - the screws can be hidden under the brackets.

Step 6 - Position baserail

Loosely put the baserail into place, making sure that it is lined up centrally to the newel post and parallel to the string edge.

Do not screw anything down at this stage.
Use masking tape, if necessary, to hold the baserail in place.

Fitting instructions, Richard Burbidge, MK1, Fusion, stair parts, Step 7, Attach connectors, Wonkee Donkee says "Take care not to mark the finish of the connectors or timber. You need to separate the connector to get to the fixing screws." Diagram of process, carefully prise off the cover cap to reveal the nut, undo and remove nut and bolt to separate the connector.

Step 7 - Attach connectors

Undo the nut and separate the two parts of the bottom handrail connector. Fix the handrail part of the connector onto a length of handrail that's longer than required and secure with the two provided screws.

Place the other part of this connector on top of the bottom newel post but do not screw into position just yet.

Slide the top handrail connector loosely over the top newel post but do not screw into position.

fitting instructions, Richard Burbidge, Fusion, MK1, stair parts, spindles, position handrail, fitting newels, fitting MK1 newels, Step 8, position handrail, Wonkee Donkee says "You will find this almost impossible without an extra pair of hands!"

Step 8 - Position handrail

Re-assemble the bottom connector, but do not tighten.

Using a spirit level, place two assembled spindles on the baserail, vertical and spaced apart.
Position the handrail on top of the two spindles giving the finished height.
Place the top connector so that it is lined up with the handrail and using a pencil, make a mark on the handrail just shy of the connector hole depth.

Tip: place masking tape on the top of the connector and mark
on this the depth of the 54mm diameter hole.

Fitting instructions, Richard Burbidge, Fusion, MK1, stair parts, newels, handrails, handrail, Step 9, Cut handrail to length, Wonkee Donkee says "You may find it a little easier if you undo the bottom connector again and remove the handrail before sawing!" Diagram, handsaw, handrail.

Step 9 - Cut handrail to length

Using a fine-toothed handsaw, cut the handrail to length.

Fitting instructions, Richard Burbidge, MK1, Fusion, stair parts, Step 10 - Mark centre position handrail, Wonkee Donkee says "Take care that you don’t mark the timber finish when sliding the top connector on the newel post."Diagram, handrail, wall bracket, newel post, centreline marked.

Step 10 - Attach top connector

Separate the two parts of the top connector in the same way that you separated the bottom connector.

Making sure that the handrail part of the bracket does not move, secure with the two
screws supplied.

Lower onto the newel post part of the connector and re-assemble.

Fitting instructions, Richard Burbidge, Fusion, MK1, stair parts. Step 11, Secure handrail, Wonkee Donkee says "Again, have someone to help you with this."

Step 11 - Secure handrail

Temporarily place two spindles near the newels as before, ensuring that the handrail sits correctly on the spindles and that the spindles are vertical.

Finally, secure the top connector to the top newel post and the bottom connector to the bottom newel post using the supplied screws

Fitting instructions, Richard Burbidge, Fusion, MK1, stair parts, Step 12, Measure and mark spindle positions, Wonkee Donkee says "My calculator will give you the centre position of the spindle brackets, not the spindle centres and will compensate for the width of your newel base The centre of the bracket will differ from the spindle centre depending on the pitch of your stairs - but you don't have to worry about that!" Diagram, view from top, baserail top face, newel base face, view from side, blue pencil, yellow ruler, yellow straight edge

Step 12 - Measure & mark spindle positions

Make a mark centrally on the baserail using the Wonkee Donkee calculator figures. These mark the position of the spindle centres. The notch on the spindle brackets will line up with your centre marks.

Make sure that you measure from the newel base and that the tape measure is flush with the top of the baserail. The tab on the end of the tape measure will lift the tape off the baserail and cause errors in your marking out. See next step for details.

Fitting instructions, prepare newels, tape measure, using tape measure, handrail, fit newels to handrail, Richard Burbidge, Fusion, MK1, Wonkee Donkee says: "Remember the old adage... Measure twice, Cut once/"

Step 13 - Using tape measure

For accurate measuring and marking out, make sure that the end of the tape measure is correctly
positioned as shown.

Being a tight angled corner means that the tape measure will not get right into the corner resulting in an error that can easily be as much as 15mm (the height of the tab), and incorrectly spaced spindles.

Fitting instructions, Richard Burbidge, Fusion, MK1, stair parts, brackets, newels, fitting newels, Step 14, Mark hole positions, Wonkee Donkee says: Remember, we are only marking the timber at this stage. Do not drill into the timber—if you do, the hole may be too big for the screw!

Step 14 - Mark hole positions

Using a bracket from one of the spindles as a guide, mark the position of the fixing holes using either a bradawl or a drill and drill bit. Make sure that the notch on the bracket is lined up centrally to your previous marks.

If using a drill and drill bit, select a drill bit that is slightly smaller than the size of the fixing hole in the bracket - a 4mm diameter bit should be sufficient. Using a slow speed, and with the drill positioned in the fixing hole, carefully drill only enough so as to make a mark on the baserail.

Repeat for all brackets attached to the baserail.

Fitting instructions, Richard Burbidge, Fusion, MK1, newels, stair parts, Step 15, Drill pilot holes, Wonkee Donkee says "Tip: Wrap a small amount of masking tape around the drill bit so you know how deep to drill." and "A pilot hole is a term used to describe the pre-drilling of a hole with a smaller drill bit and is used to guide the larger drill bit for accuracy and also to remove material in stages. In this case, we’re drilling a pilot hole to guide the screw, prevent the timber from splitting, and to make it easier for the screw to be screwed into the timber. This is more important when using hardwoods.", Diagram, 3mm drill bit, tape, 25mm drill, spindle centre, drill additional hole here, 5-10mm, baserail

Step 15 - Drill pilot holes

Remove the bracket and, using the marked hole positions, drill two pilot holes using a 3mm drill bit to a depth of around 25mm.

Drill an additional pilot hole 5-10mm uphill from your centreline mark. This will be used later to secure the baserail to the flooring. Space these about 500mm apart (every fourth or fifth spindle) - but make sure that it will lie under the brackets and hidden from view. Also make sure that a fixing hole is located under the first and last spindle brackets.

Ftting instructions, Richard Burbidge, MK1, Fusion, stair parts, Step 16, Drill baserail fixing holes, Wonkee Donkee says "IMPORTANT Do not drill through into the floor– otherwise there will be nothing for the Screw to screw into! If you don’t have a countersink bit, use a drill bit that is larger than the screw head.", Diagram, countersink bit, baserail, drill baserail

Step 16 - Drill baserail fixing holes

Identify which of the pilot holes are for fixing the baserail, and, using a 5mm drill bit, drill only the baserail fixing hole. Drill all the way through the baserail. Repeat until all the baserail fixing holes are drilled.

Using a countersink bit, countersink the hole to accept the screw so that the head of the screw is just under the surface of the timber. This is to prevent the screw from fouling on the bracket.

Secure the baserail to the floor using No 10 x 45mm (5x45mm) countersunk screws.

Fitting instructions, Richard Burbidge, Fusion, MK1, newels, handrail, step 17,fix spindles to baserail, stair parts, Wonkee Donkee says "Take care not to damage the screw heads you will want them to look good because they will be seen after the installation." Diagram, staircase, string, baserail

Step 17 - Fix spindles to baserail

Place the first assembled spindle into place on the baserail and secure using the No 6 x30mm (4x30mm) screws supplied.

Fitting instructions, Richard Burbidge, Fusion, MK1, Step 18, Fix spindles to handrail, Wonkee Donkee says "Make sure that the bracket doesn’t move as you use the bradawl. You could also use a drill as shown previously, but use a 3mm drill bit and drill the pilot hole. Take care when working above you - it’s easy to get sawdust in your eyes!" Diagram, staircase, string, baserail, spirit level, spindle, bradawl

Step 18 - Check spindle alignment

Using a spirit level, ensure that the spindle is vertical and central to the flat on the underside of the handrail. Mark the hole positions using a bradawl.

Fitting instructions, Richard Burbidge, Fusion, MK1, newels, fitting MK1 newels, stair parts, Step 19, Fix spindles to handrail, Wonkee Donkee says "Take care not to damage the screw heads you will want them to look good because they will be seen after the installation." Diagram, baserail, staircase, string, bradawl, spindle

Step 19 - Fix first spindle to handrail

Fix the spindle into place on the handrail securing using the No 6 x30mm (4x30mm) screws supplied. Leave the screws loose enough to allow movement in the spindle then place the spirit level against the spindle, ensure that it’s vertical and then tighten the screws.

Fitting instructions, Richard Burbidge, Fusion, MK1, stair parts, Step 20, Fix spindles to handrail, Wonkee Donkee says "Looking good! All that’s needed now is to wipe down your new stairs and enjoy them to the full!"

Step 20 - Fix remaining spindles to handrail

Continue until all spindles are in place then check to ensure that they are all secure.

Fitting instructions, Richard Burbidge, Fusion, MK1, newels, fitting MK1 newels, Step 21, Repeat, Wonkee Donkee says "Give yourself a pat on the back ’cos I’m sure you won’t want one from me!"

Step 21 - Repeat

If you have an intermediate newel post, you will need to repeat these fitting instructions until all spindles are in place.

Check that all screws have been tightened sufficiently.

Fitting instructions, Richard Burbidge, Fusion, MK1, stair parts, spindles, stair newels, Step 22, After care, Wonkee Donkee says "To take care of your new stairs, don’t use any chemicals or abrasive cleaners.Only clean with a damp cloth or with cleaners that are specifically designed to be used on chrome or brushed nickel finishes." image of stairs, modern staircase, interior decor, stair design

Step 22 - After care

Image of finished stairs with MK1 Spindles

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Some of the images used are © Richard Burbidge Ltd 2016 used with permission