Opening cap joint angle.

When fitting a traditionally turned opening cap, it is essential to get the mitre angle correct, when this is not cut correctly the profiles will not intersect at the correct points.

Here we will show the only way I know of getting this correct.

This is the same process for any handrail profile.

Opening cap size.

The first stage is to determine the size of cap that suits the handrail profile.

This will normally be in about 1 3/4 to 2 times the width of the handrail.

In this instance I will use a cap twice the size of the handrail.

Once you have the cap size, draw a circle the size you wish to use and draw the handrail profile centrally over the circle.

Draw the cap and handrail profile.

From the over all handrail width, draw lines down until the intersect with the opening cap over all diameter.

Cap inner radius.

To get the the inner radius of the cap, measure the distance from the widest part of the handrail to the narrowist point of the handrail.
We will call this distance “A”.

Reduce the over all radius by distance “A”.

Draw the inner circle at that radius.

N.B. when working with oval handrail use the edge of the flat on the underside as the narrowist point.

Transfer the handrail width to the cap.

Carry the measurement of the narrowist part of the handrail down to the cap inner circle.

Mark the cut angle.

Drawing the cut angle.
Once you have all these lines.

Draw a line from the widest part of the handrail, where it intersects the over all of the opening cap circle, through the intersection of the narrowist point of the handrail, where it intersects the inner cap circle and carry this on to the centre line.

Repeat this on the other side of the cap.

This is the angle at which the cap and the handrail that joins into the cap should be cut.

Mark the angle onto the cap.

Mark these angles onto the opening cap and handrail.

The angles may be drawn onto a template, this would normally be done for setting a jig for cutting the cap.

See how to cut the opening cap.

N.B.
Make sure that the opening cap grain is perpendicular the handrail grain. when the grains align the cap is prone to splitting when bolting up.

The opening cap cut.

Here you can see the opening cap and the handrail cut ready to join to each other.

The opening cap and handrail joined.

With the opening cap and the handrail cut, they can be joined together.

Cut angle.

The process for getting the cut angle on a square cap is the same as for the turned cap.

Here I have shown a close up of the joint angle.

Cut angle comparison.

Here you can see the difference between the 2 styles of cap.

The finished joints.

The two different cap styles with the joints cut in.