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).
Step 2 – Fit brackets to baserail
Measure the pitch of your staircase. You may use the printable protractor to do this.
There are other methods of measuring your stair pitch that can be used - including measuring tools and “Apps” for your phone/tablet.
Enter these dimensions into the Wonkee Donkee calculator (press Shift key and then click if you want to open a new window).
The calculator will give you the quantity of glass panels that you will need, the distance to the first bracket centre and the distance between bracket centres (the height of the handrail is determined by the panels as shown later). To confirm that everything is OK, you will also be shown the width of the Horizontal Gap and the distance between the Fusion newel post and the first panel edge - all of which must be less than 99mm to comply with current building regulations.
Step 3 - 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.
Step 4 - Position baserail
Before fixing the brackets in place, fix the baserail to the string using No. 8 x 35mm screws.
Position fixing screws under every other bracket to keep the fixings hidden.
Step 5 - Measure and mark bracket positions
Using the Wonkee Donkee calculator results, mark the positions of the bracket centres on the baserail.
These marks indicate the centre position of the brackets, not the centre of the glass panel.
Also worthy of note is that the bracket centre distance (A) to the newel will always be less than the centre distance between the brackets (C).
Step 6 - Mark baserail centre
Mark the centre of the baserail at each bracket location, across the bracket centre marks you have just made.
Step 7 - Mark bracket hole centres
Place the base of a bracket on the baserail at the marked position, lining up the notches with your centre marks. Ensure that the bracket is central to the baserail then bradawl through the fixing holes of the bracket base. Repeat this for all bracket bases.
Step 8 - Mark baserail fixing hole centre
Measure and mark a line 15mm away from your initial bracket centre marks. These will be the positions at which the baserail will be fixed to the string.
Step 9 - Mark fixing holes
1. Drill a 3mm diameter pilot hole at each bracket fixing position to a depth of around 15mm.
2. Ensuring that the baserail is centrally positioned on the string, drill a 5.2mm diameter clearance hole at each of the baserail fixing locations to a depth of 28mm - just deep enough to mark the hole positions in the string underneath.
3. Follow with a countersink bit to a diameter (Ø) of 10mm.
Step 10 - Drill string
To prevent the string from splitting, remove the baserail and using the marked hole positions, drill pilot holes into the string with a 3mm drill bit to a depth of around 15-20mm.
Replace the baserail and secure in place with No. 10 x 50mm countersunk screws.
Step 11 - Attach brackets
Attach all the bracket bases to the baserail using the No. 8 x 25mm screws supplied.
Step 12 - Attach connectors
Undo the nut located under the cover (logo) and separate the two parts of the bottom handrail connector. Fix the handrail part of the connector onto the handrail and secure with the two provided screws after using a 3mm dia. Pilot drill to a depth of around 15mm.
Place the other half of this connector on top of the bottom newel post but do not screw into position at this stage.
Slide the top handrail connector over the top newel post, and again, do not screw into position.
Step 13 - Prepare glass panel brackets
To aid the fitting of the handrail at the correct height, assemble two of the Fusion glass panels complete with top and bottom brackets. These will be used later.
This is done by first assembling the two halves of a bracket as shown. Insert the nylon sleeve into PT1 and install the rubber washer correctly over each of the clamps after removing the self adhesive backing.
Step 14 - Assemble brackets
Place the nylon sleeve fitted to the clamp PT1 into the hole of the glass panel (a). Place the bracket base onto the clamp PT1 so that it locates onto the lower boss (b). Place clamp PT2 over the glass and lined up with the previous clamp PT1 (c). Insert the two M6 countersunk screws (supplied) through the holes and using a 4mm hex key, screw in until “finger-tight” to secure the bracket (d). Do not fully tighten at this stage.
Step 15 - Assemble brackets onto glass panel
Turn the glass upside down and repeat, but attach the panel to the first bracket on the baserail. Attach the second panel to the last bracket on the baserail.
Step 16 - Position handrail
Rest the assembled handrail on top of the panels (brackets) to give the finished height of the handrail. The brackets should find their own pitch as long as you haven't overtightened them.
Step 17 - Mark handrail length
Re-assemble the bottom connector, but do not tighten.
With the handrail resting on top of the panels, position the top connector so that it is lined up with the handrail. Use a pencil to make a mark on the handrail just shy of the connector hole depth.
Step 19 - Mark centre position handrail
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 supplied screws.
Lower this onto the newel post part of the connector and re-assemble.
Step 20 - Secure connectors to newel posts
With the glass panels still in place, secure the top connector to the top newel post and the bottom connector to the bottom newel post using the supplied screws.
Ensure that the handrail is resting correctly on top of the brackets.
Step 21 - Mark out handrail
With the two panels still vertical and the bracket located centrally on the underside of the handrail, mark the centre position of the bracket onto the handrail using the notches as a guide. Remove the panels and repeat for all of the other bracket positions, or if you’re feeling confident, measure and mark the bracket positions.
Step 22 - Pre-drill handrail
Locate a bracket base into position on the underside of the handrail and mark their positions with a bradawl or drill through the fixing holes to mark their positions with a 4mm drill bit.
Remove the bracket and using a 3mm drill bit, drill a pilot hole to a depth of 15-20mm.
Step 23 - Secure brackets to handrail
Fix the bracket bases to the underside of the handrail using the supplied screws.
Step 24 - Assemble glass panels
Assemble the remaining clamps PT1 and PT2 by inserting the nylon spacer as appropriate, and rubber washer. Attach the glass panels to the brackets with the clamps and gently tighten.
To allow minor adjustments, do not fully tighten.
With all panels in place, check for alignment. Tighten brackets fully once satisfied.
Step 25 - Finishing touches
Before you put away your tools, check that all screws are in and tightened.
Place the covers over the screw heads of the brackets. These should just push into place.
Supplement
With the two panels still vertical and the bracket located centrally on the underside of the handrail, mark the centre position of the bracket onto the handrail using the notches as a guide. Remove the panels and repeat for all of the other bracket positions, or if you’re feeling confident, measure and mark the bracket positions.
