Use the router to round off the inside ovals before cutting lengthwise, that 
way you avoid risk of tearout and undercutting the base.

Graham Collins
Secret Plans
C&C 35-III #11

On 2018-07-27 8:13 PM, Dennis C. via CnC-List wrote:
Chad,

Making handrails is fairly easy.  Get a piece of teak of adequate length and 
twice as wide as the handrail height.  Mark a line down the center lengthwise.  
Using the old handrail as a template lay out the loops.  Using a hole saw with 
a diameter to match the radius of the underside of the handrail, drill holes to 
layout the loops.  At this point, you can cut the teak piece in two lengthwise. 
 To make the arches, simply connect the holes with a jig saw or a bandsaw.  I 
use a Bosch 1587 jigsaw which, in my opinion is the ONLY jigsaw that reliably 
cuts a straight line.

Now cut the ends.  Use a router to round off the underside of the loops, the 
ends and the tops.  Poof!  Handrail!

Here's one video except the guy does one at a time.  
https://www.youtube.com/watch?v=1LPPM-vZhH0

Dennis C.



On Fri, Jul 27, 2018 at 4:52 PM, Chad Osmond via CnC-List 
<cnc-list@cnc-list.com<mailto:cnc-list@cnc-list.com>> wrote:
Ok so I'll just plug the holes with a dab of 5200 and glue it up at home and 
see if I can make it look like new. If I can't at least I'll have a template to 
get my saw and router going.








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