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Thread: How to cut a through mortise in the shape of a stair handrail at a 42 dgree angle

  1. #16
    Why not use hand tools? Rasps, chisels, and good layout ought to work.

    Mike

  2. #17
    Quote Originally Posted by Jim Becker View Post
    I clearly missed that you were doing a wrap of existing posts...my bad.
    No worries. It was a difficult situation to describe. Thank you Jim for all the suggestions and help. Once I get this project done, hopefully I can share pics of the end result.
    Thanks,

    Mike DeRegnaucourt

    Axiom AR8 Pro CNC, 60-Watt Epilog Legend 36EXT, Prusa MK3 3D Printer, SE-DC16, Powermatic Bandsaw, JET Lathe, Craftsman Lathe, Rigid Drill Press, Excalibur Scroll Saw, Craftsman Tablesaw, Delta Dust Collector, JET Air Filtration, Craftsman Planer, Old Craftsman Jointer, JessEm Router Table with Porter Cable 7518 Router, etc...


    Aspire v9.5, CorelDraw 2021, Corel Video Studio 2019, ShaderMap Pro, GIMP, Mesh Mixer, Fusion 360, Sculptris, Google Sketchup, etc...

    [SIGPIC][/SIGPIC]

  3. #18
    Quote Originally Posted by Mike King View Post
    Why not use hand tools? Rasps, chisels, and good layout ought to work.

    Mike
    That is definitely a possibility. I do not know how accurate my skills are with hand tools maintaining the 42-degree angle and the oddball shape of the handrail.
    Thanks,

    Mike DeRegnaucourt

    Axiom AR8 Pro CNC, 60-Watt Epilog Legend 36EXT, Prusa MK3 3D Printer, SE-DC16, Powermatic Bandsaw, JET Lathe, Craftsman Lathe, Rigid Drill Press, Excalibur Scroll Saw, Craftsman Tablesaw, Delta Dust Collector, JET Air Filtration, Craftsman Planer, Old Craftsman Jointer, JessEm Router Table with Porter Cable 7518 Router, etc...


    Aspire v9.5, CorelDraw 2021, Corel Video Studio 2019, ShaderMap Pro, GIMP, Mesh Mixer, Fusion 360, Sculptris, Google Sketchup, etc...

    [SIGPIC][/SIGPIC]

  4. #19
    I have another idea rolling around in my head that I may try. Not sure if it will work but it might be worth a try. If it works, I will be sure to share.
    Thanks,

    Mike DeRegnaucourt

    Axiom AR8 Pro CNC, 60-Watt Epilog Legend 36EXT, Prusa MK3 3D Printer, SE-DC16, Powermatic Bandsaw, JET Lathe, Craftsman Lathe, Rigid Drill Press, Excalibur Scroll Saw, Craftsman Tablesaw, Delta Dust Collector, JET Air Filtration, Craftsman Planer, Old Craftsman Jointer, JessEm Router Table with Porter Cable 7518 Router, etc...


    Aspire v9.5, CorelDraw 2021, Corel Video Studio 2019, ShaderMap Pro, GIMP, Mesh Mixer, Fusion 360, Sculptris, Google Sketchup, etc...

    [SIGPIC][/SIGPIC]

  5. #20
    Quote Originally Posted by Mike DeRegnaucourt View Post
    That is definitely a possibility. I do not know how accurate my skills are with hand tools maintaining the 42-degree angle and the oddball shape of the handrail.
    It seems difficult but doable, the difficulty depending on the handrail profile. Since the board has to fit well on only one face you can flare out the backside of the cuts and concentrate on scribing the fit where it will be seen. I can't imagine getting a good result without hand fitting, starting with overwidth pieces carefully jointed to glue together once you have sneaked up on the profile cut. By the time you get to that point you may wish you had pulled the handrail.

  6. #21
    Quote Originally Posted by Mike DeRegnaucourt View Post
    That is definitely a possibility. I do not know how accurate my skills are with hand tools maintaining the 42-degree angle and the oddball shape of the handrail.
    ah! An opportunity to refine skills!

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