Wooden handrail profile

[Cyprusbob]

How do I recreate the profile of a wooden handrail???
I have to extend the handrail it is ovalish with a flat on the base, I need 0.9m and this is too long for my lathe as I had considered offset turning, and my largest round over bit for my router is 30 mm and I need 45 mm.
I would like any tips on jig making for this project would be much appreciated.

 

[adidat]

welcome, maybe a bigger cutter is the order of the day? you can buy handrail shaped cutters.

adidat

 

[bosshogg]

Why not dress it by hand. Plane too two templates, one fixed either end, and check with straight edge as you go...bosshogg

I never think of the future - it comes soon enough.
Albert Einstein 8)

 

[Cyprusbob]

welcome, maybe a bigger cutter is the order of the day? you can buy handrail shaped cutters.

adidat

This is a one off, I would be cheaper buying a new mahogany handrail than the cutter

 

[alan2001]

I need 0.9m and this is too long for my lathe

make it in two smaller pieces (which will fit your lathe) and then make a really nice job of joining them back together. :wink:

 

[Jacob]

Do it by hand. Sounds like you have no hollows so 0.9m would be dead easy.
Basically you make a pattern and draw the profile on each end of your blank, then join them up. No5 plane and a bit of sandpaper all you need. A band-saw would speed up waste removal.

PS if you are a beginner with planing (and you are or you wouldn't be asking this question) then this is a really good exercise. Ditto other shapes - make short lengths with different sections based on templates; triangular, octagonal, different sizes, tapered etc etc. Arrange them along your mantlepiece!

 

[Jacob]

And then move on to do the same but curved, or twisted, or both (but don't jump the gun - work up to it). Spokeshaves required. And a bigger mantelpiece.
Then you hit hyper-space by introducing hollows. :shock:
I'm not saying that I personally have progressed far up this scale of complexity, in case anybody was wondering.

 

[bosshogg]

And then move on to do the same but curved, or twisted, or both (but don't jump the gun - work up to it). Spokeshaves required. And a bigger mantelpiece.
Then you hit hyper-space by introducing hollows. :shock:
I'm not saying that I personally have progressed far up this scale of complexity, in case anybody was wondering.

Yeh, I'm sure :wink:

 

[Cyprusbob]

Thanks for all the suggestions, I ruffed it off with the 35 mm router bit, then turned a 20mm dowl and joined it to the main rail and as the original rail was cut at an angle, I squared it up and hot glued the cut bit to the opposite end of the new piece and used the electric planer and a selections of sanders to get it to the correct profile..........

Job done, and it looks good, so I have been told.

Cheers