Please help me find this router profile (or something close)

[Brian J Austin]

Hello guys,

I am on to the next step of my handrail project.

I finally decided to copy a handrail already in my house.

I have figured out most of the profile... however there is one detail that eludes me. On the bottom of the top half of the two part rail, there is a beautiful thumb-width rail that is easy to grip. Please examine the photo below. I marked the dimensions where appropriate.Pardon my MS paint skills, but I think it accurately shows what I mean.

Is there one router bit that will do that curve? Is it a combination of routing/sanding?

Any help is appreciated.

Thanks,
Brian

[Mike K Wenzloff]

Hi Brian,

If it is an exact match you need, consider having the profile made.

Else if close gets you there, for a single bit solution, the following comes close:
http://www.coastaltool.com/cgi-bin/SoftCart.exe/a/amana/hand_table.htm?L+coastest+gjmh9878ff7bcf7b+1184002 625
It's the 49554 profile which may do it.

There's also the hand tool route if there isn't a massive run needed--but then, you would need the planes to do it.

Take care, Mike

[Richard Butler]

it almost looks like a stair rail profile to me.

[Brian J Austin]

Yes, it is a stair rail. Probably about 20 linear feet. It is going in my kitchen where I took out a wall over a landing.

No, I don't need an exact copy... but really close would be nice.

Where can I get a custom bit?

[Todd Jensen]

You also might try this one: http://http://www.rockler.com/ecom7/product_details.cfm?Cat_ID=286&offerings_id=5302&catid=78&objectgroup_id=397&cookietest=1

and just adjust the bit(lower it) so that it only shapes the upper part. If you can't make a stock cutter work, I'd go get a custom one made. I was surprised to find that they generally aren't that much more to get than stock ones. As far as hand shaping a straight profile, you'd really have to have a few extra days/weeks/months on your hands, depending on your hand skills and have a hatred for power tools.:rolleyes: Since its 2007 I'd go spend $50 on the custom bit and spend an hour or two. :) I honestly think the one above will work and be very close to what you're looking for, saving you the time and hassle of waiting for a custom one. The other option is to go to your local lumber supply and take a look at some of their basic profiles, it almost looks like the really basic and popular 6010 or 6210 profile(one is just wider than the other) without the bottom, where the beading would normally be.

[Brian J Austin]

Todd... your link is broken. If it is close then I will jump on it. I want to try to keep the new handrail as close to the old as I can. I like some of the new profiles, but my wife likes the old one and thinks the new ones are too busy.

[John Durscher]

Brian,

You could try a combination of a hand rail bit and a table edge bit as shown on the CMTUSA website - look for the CMT Table Edge and Hand Rail Bits Series 856. Whiteside also has similar bits, I had trouble with their website so I went to the CMT website. To get the exact profile you'll need to do a bit more work probably with a rabbeting bit to knock off the bead the hand rail bit will leave. However, I think this combination should get you pretty close.

Three passes with a router sure beats extra time with the sandpaper!

Good luck!

John

[Tom Veatch]

Todd... your link is broken.....

The link has an extra "http://". Try this one (http://www.rockler.com/ecom7/product_details.cfm?Cat_ID=286&offerings_id=5302&catid=78&objectgroup_id=397&cookietest=1)

or DAGS for "Handrail Router Bit". Of the few returns I looked at, this one (http://www.amanatool.com/bits-fv/54262.html)looked the most promising to me.

[Al Killian]

Here is a place I found that makes costum bits. Have not used them but the have a several options for the cutter wings. http://wolfcarbide.com/Home_Page.html

[Todd Jensen]

oops, thanks Tom. :D We'll try another link here: http://www.stairworld.com/c_railcomponents.pdf and a better one for the full size profiles is here: http://www.mccoymillwork.com/pdf/mccoyWhole.pdf .