Step 1 - Determine which style you want
Immix stair parts may be fitted in one of two ways.
Either:
1. Post to post - this is where the handrail butts up to the newel post, that is, where the end of the handrail is fitted to the vertical face of the newel post, or
2. - where the handrail extends over the top of the newel post.
Step 2 – Post-to-post
These instructions are for post-to-post installation of the Immix system only.
Step 3 - Measuring 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. Whichever method you choose to adopt, make sure that your reading is accurate otherwise your calculations will be out.
Step 4 - Measure newel distance
Using an accurate tape measure, measure the distance between the newel post inside faces (ND). Enter this, along with the stair pitch, into the Wonkee Donkee calculator. This will give you the spacing and quantity of panels you will need.
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 5 - Using the tape measure
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 panels.
Make sure that you measure from the newel base and that the tape measure is flush with the top of the baserail, otherwise the tab on the end of the tape measure will lift the tape off the baserail and cause errors in your marking out.
Step 6 - Mark bottom and intermediate newels
Place an offcut piece of baserail onto the string and make a pencil mark where it touches the newel face.
Continue this line along the side face of the newel at the same angle as the stairs and baserail (shown).
Make a mark at the centre of this line (effectively the centre of the newel post).
Measure up 175mm from this point and, using a square, mark a line showing where to cut the newel. Continue this line all the way around the newel post using the square.
Repeat for all intermediate newels on stairs if present.
Step 7 - Mark top newels
Mark the top Newel Post in the same way, but this time measure up only 125mm from where your marks intersect.
Step 8 - Trim newels to height
Trim all Newel Posts to your marks using a fine-toothed handsaw. Ensure that the saw is kept level and straight at all times, taking care when breaking through to avoid splintering the timber.
Step 9 - Intermediate newel post
If the distance between newels is greater than 2400mm, then you will need to fit an intermediate newel base. These are available in lengths of 510mm, 700mm, and 915mm and are pre-drilled to accept the IMMIX newel post. They will, however, require fitting to your stairs which will entail carefully slotting the base to fit over the string, and removing material so that it fits the profile of the step.
Ensure that the finished height of the newel is 175mm above the intersection of the newel post centreline and the finished height of the baserail as shown below.
Step 10 - Measure existing newel
Measure the width of your existing newel post - this should be no less than 90mm x 90mm square and installed central to the riser and string. If the section size of the newel base is less than this, it will have to be built up by cladding each side equally to get to the required size. Use adhesive and pins to fix in place, cladding the newel so that it ends flush with the top of the newel base.
Step 11 - Mark and drill newel bases
If using existing bases, locate and mark the vertical centreline of the newel face (stand on the step, turn towards the newel - it’s the face facing you). Measure down 125mm and mark the centre point for the 35mm diameter hole. Drill hole to a depth of 62mm. (A)
Locate and mark the centre on top of the base by drawing a diagonal line across each corner. Drill a 50.8mm diameter hole to a depth of 35mm. Follow with a 13mm drill bit to drill a hole to a depth where it intersects with the 35mm diameter hole. (B)
Step 12 - Install baserail
Lay the baserail on top of the stair nosing and offer up to the side of the newel bases.
Mark a vertical line following the inside face edge of each newel base.
Remove and carefully and cut to length.
Step 13 - Drill and fix
Drill clearance holes for the screws about 150mm from each end and spaced equally every 400mm or so. Drill 4.5mm diameter hole through the bottom of the groove of the baserail and then countersink.
Position the baserail between the newel bases, ensuring the rail is central to the bases. Drill pilot holes through the baserail into the string.
Before securing the baserail to the string, ensure that all debris is cleared from within the rail groove.
Reposition the baserail and fix to the string, making sure that all
the screw heads are below the surface and do not project into the
groove.
Step 14 - Install the top and bottom newels
Position the newel base connector (IMNBC) on top of the newel base and mark the position of screw holes. Pilot drill, using a 2.5mm drill bit, and fix the connector to the base using the screws supplied.
If the newel base is larger than 90mm x 90mm square, then ensure that the connector is lined up correctly, using the previous diagonal lines as guides.
Step 15 - Drill and fix top and bottom newels
Insert the circular locking nut into the 35mm diameter hole ensuring the arrow is facing outward and up. Insert the threaded bar on the bottom of the newel post into the newel base so it locates in the locking nut. Tighten with an allen key until the newel post starts to be drawn down ensuring that the newel alignment will sit within the newel base connector (IMNBC).
Tighten until fully down. Repeat for top newel.
Step 16 - Intermediate newels
Cut the Intermediate newel post to length. Choose from the list below depending on the pitch of your stairs. If the pitch falls between two listed pitches, adjust the newel length accordingly.
(see table below)
Step 17 - Install rake connector
Insert and fix the intermediate newel post into the newel base following the same instructions for the top and bottom newels.
Place the intermediate rake connector (IMIRC) onto the top of the intermediate newel and mark the position of the screw holes on top of the newel.
Step 18 - Secure connector to newel
Using a 3mm bit, pilot drill the fixing holes.
Secure the intermediate rake connector to the newel post using the supplied screws then set the arm on the connector to the same pitch as the stairs and tighten.
Step 19 - Install handrails - mark and cut
Place a length of handrail on the stair nosing up against the newel bases and mark the handrail from the inside face of the bottom newel base and the inside face of the top newel base.
Subtract 14mm from the length, mark and cut to the angle of the newel. This will ensure the correct rail length when using the connectors.
Step 20 - Secure connectors
Offer the bottom rake connector (IMBRC) to the bottom end of the handrail ensuring the top of the connector is as close to the top of the handrail as possible. Pilot drill through the screw holes using a 3mm drill bit and secure with the screws provided.
Fasten the top rake connector (IMTRC) to the top end of the handrail and fit in the same way.
Step 21 - Install handrails - mark and cut
Cut 2 x battens at 795mm high x 50mm wide x 8mm deep cut at the stair pitch and locate in the baserail groove.
Offer the handrail between newels and over the intermediate rake connector (IMIRC) ensuring that the bottom of the handrail groove is sitting on the top edge of the battens.
Step 22 - Mark position of top connector
Using the location grooves on the sides of the connector, mark the location of the bolt holes for top and bottom rake connectors on the newel posts.
Step 23 - Install handrails - marking out
Using a square, run a line around to the opposite face of the newels and make a mark to show the centre of the newel.
Step 24 - Secure connectors
Drill a counter bore hole using a 16mm diameter spade bit to a depth of 20mm.
Drill a 10mm diameter clearance hole through the newel.
Step 25 - Install handrails - secure to newel
Offer the handrail between newels and onto the intermediate connector. Secure the rake connectors to the top and bottom newels using the bolts and washers supplied.
Step 26 - Secure connectors
Secure the handrail to the intermediate connector by drilling two pilot holes through the intermediate fixing arm located in the rail groove and fix using the screws supplied.
Step 27 - Measure for glass panels
Measure 60mm from the newel bases along the top face of the baserail and make a mark. This will be the position of the side edge of the first and last glass panels in the run.
Repeat for each baserail length.
Step 28 - Cut fillets
Cut fillets for the bottom of the stairs for the handrail and base rail.
Ensure that fillets are cut to the angle of stairs. Drill a 4mm hole down through the centre of the fillet parallel to the cut sides and countersink so the screw head will be below the top of the fillet. You will need to trim approximately 7mm off the top handrail fillet to allow for the connector.
Pilot drill and fit the bottom fillet using No.6 x38mm screw.
Step 29 - Check positioning
Check that the top fillet is positioned correctly before fixing it into place. To do this, place the bottom edge of one of the glass panels into the base rail groove and pivot to fit into the handrail groove. Ensure that the glass butts up against both fillets and check that the gap between the glass edge and newel post is the same near the handrail as the gap near the baserail.
Once you are happy that the glass panel is parallel to the newel post, remove and place safely to one side.
Fix the top fillet into the handrail groove by pilot drilling with a 2.5mm drill bit and then securing using 63mm No 6 screw.
Step 30 - How many panels?
To work out how many panels are required and the size of fillets, measure the distance between the two marks on the baserail.
Divide this measurement by 350. Round the figure down to the next whole number (number of panels required).
Multiply this number by the panel dimension according to the pitch of stairs.
Subtract this figure from the original measurement.
Divide by number of panels (less 1) to get fillet size
Example –
Measurement between marks = 1820mm
1820mm divided by 350 = 5.20, rounded down to 5
Pitch of stairs is 42 degrees so panel dimension is 269mm x 5 =1345mm
Original measurement 1820mm minus 1345mm = 475mm
475mm divided by 4 (number of panels less 1) = 118.75mm (length of fillet)
Please note - maximum length of fillet must not exceed 129mm. If maximum length is exceeded add another panel by rounding up (after dividing by 350) and re-calculate.
Step 31 - Install glass panels - sealant
Cut all fillets to length and drill a clearance hole parallel to the cut sides through the centre using a 4mm bit and countersink so the screw heads are below top of fillet.
Cut all decorative plastic strips (supplied with the rails) to suit using a junior hacksaw.
Apply a bead of clear silicone to both the handrail and the baserail grooves ensuring that you also put a bead on the side wall of the handrail groove.
Step 32 - Secure connectors
Insert the glass panel into the top and bottom grooves and up against the previously installed fillets. Install another set of top and bottom fillets, pilot drill and secure.
Depending on how many panels are used and the gaps between them, you may have to insert the last two or three panels into the groove first before installing fillets.
If this is the case, wrap some cardboard around the side edge of the panels and insert,
carefully allowing them to butt up to each other.
Once all panels are in, separate the panels by installing the fillets between them
and securing the fillets in place as previous.
Push the decorative plastic strips into the grooves to hide the timber fillets.
They should be a good fit, but because of manufacturing tolerances of the glass and the
grooves, the glass may seem a little loose. If this is the case, secure with clear silicone.
To finish, glue the newel caps to the top of newel posts and insert all
bolthole cover caps by tapping them in.
Silicone all of the square timber cover caps in the
newel bases.
