How to Design Stair Handrails

Measure the stairwell that you are designing the handrail for and determine the overall length. For added safety, it is best to extend the rail past the first and last steps. Add 2 feet to the measurement for the end pieces.

Set your saw guide to a 45-degree cut. Cut the long piece of the handrail so that the miter cut is on the inside of the wood piece. Cut the short pieces so that the miter cut is on the outside of the pieces.

Determine the design you wish to cut into the handrail. Typical designs are usually softened edges with some routed trim at the bottom edge. Gently shave the wood to form your design.

Sand down the entire handrail first with 90-grit, and then 180-grit sandpaper. The handrail must be completely smooth. Sand the designs using an edging sander.

Coat the handrail with two coats of varnish to bring out the wood’s grain and protect the wood. Always brush on the varnish going with the wood’s grain and let it dry completely between layers.

Wrap the ends of the stair handrail with painter’s tape. Make sure it is flush with the cut edges.

Mix up the 90-second epoxy and paint a thin layer on both edges that you are bonding together. Hold the edges in place, focusing on the edges forming a clean fit. Peel the painter’s tape off after 5 minutes and let the epoxy set for 24 hours for maximum strength.