Recent Staircase

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katellwood
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Recent Staircase

Post by katellwood » Tue Mar 31, 2020 8:34 pm

Thought I would like to share the build of this flight of stairs

This staircase and balustrade also acts as the support for the upper landing with the client wishing to maintain a view to some original leaded windows found in the property (which dates from the 18th century and was originally a pub/Inn) and which I have previously restored and framed in oak.

In addition beneath the main stairs is another flight which accesses the cellar and was extremely difficult to design owing to the limitations of the floor space area available

All the newels are constructed from 90mm square u/s softwood (made up of two pieces of 50mm glued back to back to prevent and movement. These were then clad in 20mm panelled oak creating 130mm square newels

Hope the pictures help in understanding this

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A full size rod in plan was created on an 8 x 4 sheet of mdf to locate all wall and wall corner locations and the radius in plan.

From the rod a jig was set out and built out of ply, 2x2’s and 3 layers 6mm mdf glued together and clamped with ratchet straps to facilitate making the curved string (sorry no photo’s of this however I still have the jig if anyone any pictures).
Upon making the jig it was then placed on the rod and riser lines of the cured section projected onto the jig followed by tread lines, in essence I turned the jig into a curved rod which included the top and bottom lines of the string.

As this setup was too big for my airbag and also the reason for three layers of 6mm mdf I covered to area of the string on the jig with clear packing tape then laminated 4mm birch ply to a thickness of 28mm. This was done in two stages with the first stage being glued on top of the second stage in an attempt to eliminate springback.

Lengths of materials/offcuts kicking around the workshop were utilised to clamp the ply to the jig, I also glued strips of hardboard with CA to these offcuts on the outer edges to spread the clamping effect.

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Once the ply had dried I resawed a piece of oak to 5mm on the bandsaw and ran it through the drum sander down to 4mm. This again was placed on the jig and all clamped up again

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When everything was fully cured the jig was used as a setting out rod for the curved string and a reverse curved base was made for the router, the base had a straight edge at a right angle to the curve to allow it to run alongside of another straight edge

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The riser housings were created in a similar way with underside wedge room also being routed (again a lack of pictures here). The housings in the upper newel were also routered and a dry fit was attempted. This is where working alone can be a right pain trying to balance/support everything to check all the joints.

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This whole upper curved section was glued and wedged, in addition I screwed the treads through the back of the curved string to keep everything tight. (both treads and risers are made from solid oak as opposed veneered mdf for the risers)

I then made a short section of two treads with closed strings which went against walls, this was attached to the curved string with a series of dominoes

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To further make this joint more secure I routered a couple of 30mm x 6mm deep grooves into the back of the curved and straight string and glued some appropriate strips into the groove to improve strength.

This assembled upper section was to be jointed into two newel posts half way up the full stair where it came into contact with walls (all will become evident as I proceed).

The next stage was the lower section which was to be cut or open string. I would have liked to have included brackets to the design as I think they enhance a stair plus they can hide a multitude of fixings however, on this job it was not to be however, I did incorporate mitred breadboard ends to all the lower treads. Again I did not photograph the construction of the cut string but have a sketchup of how the construction went

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All joints were fitted and as much of this section was glued in the workshop to as larger sections as were practicable to facilitate transport and access. Scotia moulding was machined added to the underside of the treads.

NB, on a cut string to secure the riser a screw can be used behind the scotia and behind the tread prior to it being fitted

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Re the assembly, I will show what photo’s I have taken, any questions please ask.

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A bullnose step was made however the fitting of this awaits until a new floor is fitted and I can scribe the riser to the floor (its not level)

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To follow is a the few photo’s I took re balustrading I know I should have taken more but I just get engrossed in the workshop and in essence I forget

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Currently stalled from the final finish as waiting for some slightly longer wrought ironwork being powder coated, when fully finished with snagging, final sanding and oiling I will post more photo’s

Please any questions, comments constructive criticism please don’t hesitate

Thanks

Chris

Leveller2911
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Re: Recent Staircase

Post by Leveller2911 » Wed Apr 01, 2020 5:38 pm

Hi Chris,
Lovelly job and I would love to learn more about Staircases but because I rarely get asked I rarely get involved in them. I like doing curved work (windows,doors etc) because its different and takes some thinking about and you made a fab job of that. Will it be oiled and do you worry at all about central heating shrinking/moving the oak at all?.

Cheers Leveller

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Re: Recent Staircase

Post by MJ80 » Wed Apr 01, 2020 8:33 pm

Fantastic job, I would love to have a go at doing a handrail like that. I've only done a few stairs but have always enjoyed them.

woodsmith
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Re: Recent Staircase

Post by woodsmith » Thu Apr 02, 2020 8:31 am

Fantastic job, I hope you have an appreciative customer. It's put me to shame, I've just bought in a flat pack staircase!
Keith

thatsnotafestool
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Re: Recent Staircase

Post by thatsnotafestool » Thu Apr 02, 2020 10:02 pm

That's fantastic. How did you make the balustrades ?

SWMBO wants me to replace the newels and balustrades with something similar. Where are you based...as I think I'm chickening out seeing the quality of your work.
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The advantage of a bad memory is that one enjoys several times the same good things for the first time.
Friedrich Nietzsche

furynaturre
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Re: Recent Staircase

Post by furynaturre » Fri Apr 03, 2020 3:54 pm

That is cracking piece of work!

Especially as you only needed a club hammer to get it in!, I always seem to need the sledge. :roll:

I particularly like your use of the bobbin sander, and how you've cased the newels.

Top man

James

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Re: Recent Staircase

Post by Rogerdodge » Fri Apr 03, 2020 4:58 pm

Beautiful work. Thanks very much for posting.

jfc
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Re: Recent Staircase

Post by jfc » Sun Apr 05, 2020 4:57 pm

:o :o :o Fantastic craftsmanship ! Looks lovely !

katellwood
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Re: Recent Staircase

Post by katellwood » Sun Apr 05, 2020 8:18 pm

Thanks for all the kind and encouraging comments its appreciated

TNAF this may interest you, one I did last summer

Was asked to quote for a new oak staircase. my first question was "are you going to carpet it" yes was the reply. I said "then you don't need a new staircase and this is what I did

firstly a few photo's of before

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and what I produced

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And after the carpet

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if I can assist in any way please don't hesitate. I'm near Dartford, Kent

thatsnotafestool
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Re: Recent Staircase

Post by thatsnotafestool » Sun Apr 05, 2020 9:20 pm

Thanks for the photos but I'm after something as sinuous as your other one.
The advantage of a bad memory is that one enjoys several times the same good things for the first time.
Friedrich Nietzsche

Meccarroll
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Re: Recent Staircase

Post by Meccarroll » Tue Apr 07, 2020 8:04 am

thatsnotafestool wrote:
Thu Apr 02, 2020 10:02 pm
That's fantastic. How did you make the balustrades ?

SWMBO wants me to replace the newels and balustrades with something similar. Where are you based...as I think I'm chickening out seeing the quality of your work.
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Is this your current staircase Roger?

Meccarroll
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Re: Recent Staircase

Post by Meccarroll » Tue Apr 07, 2020 8:13 am

Fantastic Job! I particularly like how you curved the handrail on the bottom newel to to blend in with the newel on the basement, clever bit of thinking there. This shows true craftsmanship and you have at your fingertips. Well done!

katellwood
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Re: Recent Staircase

Post by katellwood » Sat Jul 25, 2020 4:35 pm

Have been wanting to post these for a while now, images of the completed flight

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Rogerdodge
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Re: Recent Staircase

Post by Rogerdodge » Sun Jul 26, 2020 8:29 pm

Very fine piece of work. Looks terrific.

Roger-M
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Re: Recent Staircase

Post by Roger-M » Fri Jul 31, 2020 10:48 am

Fabulous. I can't say I fully understand the process, and I wouldn't know where to start on that balustrade, but I certainly appreciate the end result.
Cheers, Roger

JonR
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Re: Recent Staircase

Post by JonR » Sun Aug 02, 2020 10:39 am

Very nice Chris, top draw job :)

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