Step 1 - Measure newel post distance
First of all, you will need to work out if you need an intermediate newel post fitted or not, and how many spindles you will need.
Step 2 – Measure handrail height
Measure the distance between the inside faces of the newel posts, or the distance between the newel post and the wall.
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.
Step 3 - Check spindles
There are two types of spindles available in the FUSION range.
The fitting instructions are different for each type.
Before going any further, confirm the type of spindle you are using.
Step 4 - Mk2 spindles - assembly
The MK2 spindles are comprised of the spindle and brackets. The spindles are pre-assembled with one part of a two piece bracket (Bracket 2). The other part of the bracket (Bracket 1) is supplied loose. This is the part of the bracket that is fixed to the handrail or baserail.
You will need to assemble two of the spindles. These will be used later to determined the final height of the handrail. Fix the spindle with bracket 2 to the base bracket 1 using the supplied No 8 x16 screw. Do not over tighten the screw at this stage - we need to be able to adjust the bracket position.
Step 5 - Measure for baserail
Before fixing the spindles, the handrail and baserail will need to be installed.
Using the measured distance between newel bases and/or between newel base and wall, mark and cut the baserail to length.
Step 6 - Position baserail
Loosely place the baserail into place, making sure that it is lined up centrally to the newel post and parallel to the floor edge.
Do not fix down at this stage.
Step 7 - Mark centreline
With the baserail correctly positioned (A), make a small mark on the wall to indicate where the centre line of the baserail falls (B).
Using a large level (or straight edge and level), mark a vertical line from about 850mm to about 950mm from the floor. This will give the centreline of the handrail (C) & (D).
Step 8 - Position spindle
Place two assembled spindles vertically and spaced apart, on the baserail.
Rest a length of handrail or handrail off-cut on top of the spindles to give the finished height of the handrail.
Step 9 - Mark position of handrail
Mark a line on the newel post about 5mm below the top of the handrail.
If you have intermediate newel posts, mark the height on these as well.
Step 10 - Mark centre position handrail
Place a wall bracket on the end of the handrail and position the wall bracket against the wall with one of the fixing holes at the top. Make sure that the previously marked centreline passes through the middle of this top hole.
Use a pencil to mark the centre of this hole as well as the centre of the other two fixing holes.
Step 11 - Drill wall
Remove the handrail, wall bracket and panel. Drill a hole in the previously marked positions to suit a wallplug or fixing appropriate for the type of wall the wall bracket will be fixed to.
Secure wall bracket to the wall using the screws provided.
Step 12 - Cut newel post to size
Using a fine-toothed hand saw, cut the newel post at the place previously marked.
Step 13 - Mark handrail length
With the handrail in place and in the wall bracket, make a mark about 5mm in from the inside face of the newel post as shown.
Step 14 - Cut handrail to length
Remove the handrail and using a fine toothed hand saw, cut the handrail at the place previously marked.
Step 15 - Install handrail
With the handrail now cut, place the handrail back into the wallbracket, and at the other end, using the landing connector, position the handrail on the newel post. Do not secure at this stage.
Step 16 - Mark bracket positions
Using a tape measure and sharp pencil, measure the centre position of the brackets. To make it easier, the printout from the Wonkee Donkee calculator will give you all the dimensions you need.
Step 17 - Drill pilot holes
Using the marked hole positions, drill a pilot hole using a 3mm drill bit to a depth of around 25mm. Drill an additional pilot hole central to the width of the baserail and 12mm from the bracket fixing hole. This will be used later to secure the baserail to the flooring. Space these roughly 500mm apart - but always 12mm from the bracket fixing hole. It does not matter whether it’s to the left or to the right of the
fixing hole, but make sure that a fixing hole is located under the first and last spindle brackets. Make a pencil mark by this hole immediately after drilling to identify it later as the baserail fixing hole.
Step 18 - Drill and secure baserail
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.
Step 19 - Fix bracket to baserail
Place the base brackets (bracket 1) into place on the baserail and secure using the No 8 x25mm (4.5x25mm) screws supplied.
Step 20 - Fix spindles to baserail
Remove the base bracket (bracket 1) from one of the spindles that you assembled earlier and, using the supplied screw, temporarily attach the spindle to the bracket you’ve secured to the baserail.
Using a spirit level, make sure that the spindle is vertical and then mark the handrail where the notch is at the centre position of the bracket. Undo the screw and remove the spindle then repeat for the other spindle positions.
Step 21 - Fix brackets to handrail
Fix base brackets (bracket 1) to the underside of the handrail using the No. 8 x25mm screws provided. Position the brackets centrally to your marks. Using a bradawl or a 3mm drill bit to make a pilot hole - this will enable the screw to go in easier, particularly when working with hardwoods.
Step 22 - Fix spindles to handrail
Once all the brackets are in place, fix the spindles to the brackets using the No. 8 x16mm screws supplied. Ensure that the screws are tightened, but do not over-tighten.
Step 23 - Secure spindles
Continue until all spindles are in place then check to ensure that they are all secure.
Finally, using the supplied screws, secure the brackets to the handrail and newel post.
Step 24 - 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.
