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BEFORE YOU START:
 The following instructions are designed to help you meet safety regulations laid down under current Building Regulations.
The most important rules about safety state that the height of the handrail on the stairs and landing should not be less than 1000mm, and that a 100mm ball should not be able to pass between spindles/balusters at any point.
| INTERNAL NEWEL MEASUREMENTS | 82mm Newel | 65mm Newel |
| Length of Post from Floor to top of Post | 1,260 | 960 |
| Length of side fixing post from floor to top of post | 1360 | 1160 |
| Depth of cut for side-mounting joint lip cut out | 8.5 | 0 |
| Depth of shade bit (35mm) | 50 | 40 |
TOOLS REQUIRED:
You will already have most of the tools needed to fit new TWA Banisters.
The following are the most useful:
- Electric Drill: For pilot holes for fixings and other jobs. HSS bits required for the fasteners
- Panel saw: For cutting base and handrails.
- Tenon saw: Supports the bottom of the balusters/spindles.
- Adjustable bevel: A device for measuring and marking angles. One of the few tools you may not have, but worth buying.
ACCESSORIES:
Woodworking Adhesive; Panel Pins; Glass Paper (fine Grade)
BALUSTERS/SPINDLES and FILLETS - calculating how many you need:
To calculate how many you need on the rake, divide the distance between newel posts by 112 for 42mm balusters. To calculate the number of landing spindles required, measure the horizontal distance in mm then divide by 112. (Eg, if the horizontal distance is 896mm, divide by 112 = 8 balusters/spindles).
(Alternatively fill in and fax/e-mail TWA Banisters the documents found at our help desk for our FREE planning service and we will work this out for you.)
1. FIXING NEWEL POSTS: |
When existing Newel post is removed note how it has been fixed. New newel posts must be located in the same position and can be fitted using either the Newel Pin or the Newel side fixing kit depending on circumstances. Both types of fixings can be used together for added strength. It is essential that newel posts are totally rigid when fixed and fixings must always be made into substantial timbers. Check that the newel post is vertical.
Click on right hand image for enlargement.
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2. BASERAIL: |
The next stage is to fit the Baserail. This must be cut to the angle of the stairs. To find the angle of the stairs either make a template using cardboard or use and adjustable bevel.
Measure and cut both ends of the baserail. Take time to ensure a clean and correct cut. Drill and countersink holes, then screw and glue the baserail to the string. Use at least 50mm screws at maximum 300mm centres
Click on right hand image for enlargement.
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3. HANDRAIL: |
The handrail should be cut to the same angle as the baserail. To connect the handrail to the Newel posts on the staircase use the L Bracket kit for STAIRS. It is essential to position the handrail at the minimum height. The handrail and baserail should be parallel from bottom to top.
Click on right hand image for enlargement.
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4. BALUSTERS/SPINDLES & FILLETS: |
The spindles should now be fitted.
To calculate how many spindles are required on the rake, divide the distance between newel posts by 112mm for 42mm balusters.
- To give the required length and angle of cut, the first spindle should be measured by standing it against the stair base and top rails and the angle accurately marked. This spindle is used as a template to mark the angle for the rest of the spindles.
- The SABS standard distance between each spindle must not be more than 90mm, to have equal spacing, adjusting the first and last fillet between posts which must be shortened in distance to the posts. The remaining fillets can thus be spaced equally at 90mm apart (which must be cut at the correct angle as in step a).
- The spindles are spaced using fillets. Having adjusted the first and last fillets as required, fit spindles into position, cross pin and glue. Also pin fillets top and bottom.
5. LANDING BALUSTRADING:
Where a landing returns on itself (ie: 180°) it is necessary to use a quarter turn. It may be necessary or desirable to trim one leg of the quarter turn so that the landing balustrading can be taken closer to the newel post and the edge of the stairwell, thus maximising landing space. Where the landing is at right-angles to the stairs (ie 90°) it is not necessary to use a quarter turn because you will have a newel post in place.
To fit the quarter turn & joining of hand rail, drill a 6mm hole to a depth of 38mm into the centre of the end of the quarter turn which will be secured to the handrail.
Drill a 9mm hole 44mm deep into the centre of the handrail. Drill a 25mm access hole into the underside of the handrail with the centre of the hole 44mm from the end of the rail.
Click on right hand image for enlargement.
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Screw the thread of the bolt into the hole in the quarter turn. Slip the handrail onto the exposed bolt and, via the access hole in the rail, fit the nut.
Before tightening the nut apply woodworking adhesive to the join between the rail and quarter turn. Align the parts then tighten the nut. Remove excess adhesive squeezed out of the join. Leave for several hours for the adhesive to set, then sand the join for a perfectly smooth finish.
At the other end where the handrail meets the wall, use the half newel post. Fit to the handrail in the same way as to the whole newel post and then cut the base of the newel post to the required length and screw the base to the wall.
Cut the baserail to the required length then drill, countersink, glue and screw the baserail to the floor. Use at least 50mm screws. If using the horizontal turn, you will need to mitre join the baserail. Once the landing handrail and baserail are in
position, the landing spindles can be cut to the correct length.
Once the landing handrail and baserail are in position, the landing spindles can be cut to the correct length. Mark off one spindle and cut to length. Check its accuracy along the landing and cut the remaining spindles to length.
NOTE - Important. Spacing of spindles is achieved with fillets. It is necessary to trim fillets to a maximum 80mm on the landing to comply with safety regulations.
Follow the same procedure as on rake to achieve equal spacing. Equalise spacing between first and last landing spindles. Once achieved, glue and pin spindles and fillets into position.
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6. PROCEDURE FOR STAINING AND VARNISHING STAIRPARTS
Smooth surfaces down with fine glasspaper. Wipe off all traces of dust. Treat with gloss polyurethane varnish, Quick Drying Woodstain or High Performance Woodstain in the colour of your choice.
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