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Thread: Chinese Chippendale Handrail

  1. #1

    Chinese Chippendale Handrail

    I am working pretty much alone at the Hall of the Mountain King. The current activity is the porch handrail. I have made the prototype panels.
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    These will be framed into the openings. Now I have to make four more sets. Here is the material.
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    Today’s task was to surface four sides. The material got thinner and straighter as I went.

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    Here is the aftermath, six bags of shavings. I was thankful for power tools.
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    it was a good day.
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  2. #2
    Join Date
    Mar 2003
    Location
    San Francisco, CA
    Posts
    10,304
    What is your joinery for all those parts meeting at odd angles? Mortise and tenon? Domino? Simple nailed butt joints?

  3. #3
    Quote Originally Posted by Jamie Buxton View Post
    What is your joinery for all those parts meeting at odd angles? Mortise and tenon? Domino? Simple nailed butt joints?
    Trim head screws and Titebond 3 and butt joints for most. The middle of the main diagonal is cross lap so it is quite strong. Trim head screws are surprisingly strong. I stood on the prototype laid flat and supported on the short sides to test it. The key is tight joints so the glue helps. I have turned a carpentry job into something requiring furniture level accuracy. I like that part.

  4. #4

    Side Panel Assembly

    The side panels consist of five vertical pickets screwed and glued to top and bottom pieces. My assembly jig is a right angle made of 3/4 plywood strips screwed to the assembly table and fixed and movable wedges the hold the parts square. I use plywood spacers between the pickets. Bessey K body clamps apply pressure to the glue joint.
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    The top and bottom pieces are marked on one side for drilling the pilot holes and on the other for outlining the glue joint.
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    The drill press fence and laser guides make the pilot hole alignment fast and accurate.
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    Applying glue to multiple parts at once speeds up the operation.
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    Now, we have to assemble, clamp, and, drive the screws in. I used 2 1/2 inch deck screws. They will not show.
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    The tedious part is cleaning up the glue squeeze-out. The end result is a strong, square panel. It took about 4 hours to assemble 8 panels.

  5. #5
    This one passed the squareness test.
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    I will have to shut down the handrail project for a few days so that the trim carpenter can finish up in the shop. I need to clear the shelves and tools from around the exterior walls so they can access the windows, doors, and baseboard. I am happy for the help. I want to be finished on construction.
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    Last edited by Thomas Wilson; 08-31-2020 at 8:51 PM.

  6. #6
    I am finally back to installing the Chinese Chippendale panels on the screened porch. I clamped a side panel in place to check the reveals. Looks good to me and more importantly to Janicewhokeepsmehumble.

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    I have to think out the order of assembly very carefully. There could be interference that prevents driving screws if I get it wrong. The whole assembly has to be removable so that the screen can be replaced if it gets damaged in the future.

    PS I rotated this jpeg before uploading but the displayed image is still sideways. Sorry.
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    Last edited by Thomas Wilson; 05-14-2021 at 2:05 PM.

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