Step 17 - Mark newel post for bolt fix method
The handrail may be fixed using the bolt fix method. This entails fixing the handrail plate to the handrail, and drilling a hole in the newel for the bolt.
To use this system, insert the spigot part of the newels into the newel bases but do not fix just yet. Place the handrail between the newel posts, set to the correct height. Use a clamp and timber offcuts to achieve this.
Step 18 – Attach handrail using bolt fix method
With the handrail in position so that the top of the handrail is at least 900mm from the pitch line/stair nosing and the same height at both ends, make vertical marks at each end of the handrail following the inside face of the newel posts.
Continue the mark all the way around the handrail using a square and cut with a fine-toothed handsaw.
Step 19 - Prepare bottom newel
Find and mark the vertical centreline of the post on the bottom newel.
Measure down 88mm from the top face and, with the use of a square, mark a horizontal line.
Where the marks cross, drill a hole 8mm diameter through the newel post and into the handrail to a depth of about 25mm. Counterbore the newel hole to take the screw head supplied with the bracket to about 20mm deep.
Step 20 - Prepare top newel
Measure the distance between the newel post inside faces (ND). Enter this into the Wonkee Donkee calculator along with the stair pitch. This will give you the quantity of spindles and their spacing.
Note: Be aware of errors that can creep in when measuring the newel distance with a tape measure, particularly when measuring right into an angled corner. See next step.
Step 21 - Recess newel
Remove handrail and clamps. Align the handrail plate with the hole just drilled into the newel and mark the outline of the plate. Chisel out forming a recess to the depth of the plate.
Step 22 - Fix handrail plate to handrail
Insert the spigot part of the handrail plate into the hole in the handrail and mark the fixing hole positions. Pilot drill using a 2.5mm drill bit. Fix plate to handrail using the supplied screws. Repeat for the other end of the handrail.
Step 23 - Secure handrail
Remove the bottom newel and apply a small amount of a proprietary PU adhesive (not Fast Grab) to the end faces of the handrail.
Assemble the handrail and newel so that the fitted handrail plate sits in the recess previously formed, and insert the washer and bolt into and through the newel and finger tighten.
Repeat so that handrail is attached to both newels
Step 24 - Secure newels
With the handrail fitted to the newels, lift the newel/handrail assembly out of the newel bases. Ensure that both the hole and spigots are clean and free from saw dust.
Apply a large bead of a proprietary Fast Grab PU adhesive to the inside circumference of the newel base and a small bead to the underside flat surface at the base of the newel (not spigot) as shown.
Note: Do not use any other type of adhesive.
Step 25 - Secure handrail
Fully tighten the bolts in the top and bottom newels using a socket & wrench until the shoulders on the handrail are flush against the newel faces. Clean off excess adhesive.
Allow the adhesive to set for 30 minutes minimum.