Sloped Curved Stairway railings?

[CMC Fab]

Okay I hope this makes sense. I am a self taught Fabricator in which
I have been in buisness for about 2 years. Im having a problem with
trying to figure out the best way to bend Railing frame rails on a
radius slope. I have a 3 wheel bender which I use for arching tubing
and I can bend up too 1/2" x 1.5" the hard way.

Now, my question is how do they keep the frame rails parallel to the
ground. If I just make the radius of lets say 1/2"x1.5" flat bar,
and i set it at the top of the stairway parallel to the ground. Then
at the bottom of the stairway the flat bar will be at about 30-
45deg. depending on the length of the stairway.

I hope this is making sense. I once made some radius rails and took
it to a Iron work shop thinking they had a special way of
straightening it out to stay parallel and all they did is Heat it
and bent it with a big crecent wrench. I could of done that. So when
it was finished, you could see all the spots that were bent about
every 3-4 inches. I scraped it and did it myseld but took forever.

Please advice with any ideas or suggestions. I will try and post
some pics of recent work in the photo section.

Thank You.
Charles

[zapster]

sorry man...i'm totally lost..

pics will help in the recovery process...

...zap!

[CMC Fab]

Sorry, Here is one I did with a double radius on 2 different planes, The top rail I had to keep at 36" to the steps and the bottom I kept with the top of the wall. It was pretty difficult being that it was my first time but came out pretty good.

I guess what Im talking about is similar to what they do with spiral curves or stairways.

[CMC Fab]

Another example I found. How to keep both top and bottom frame rails on the same plane as the steps or footing. Or maybe Plane is not the word I should be using.

[tapwelder]

You got to make two twisting tools. Basically they are shaped like pipe wrenches. Though the teeth of a wrench mar the surface. Make them out of 3/4 in sched. 40 or something stout but managable. You just have to go to the site and make a pattern. I usually make a pattern with a the bottom channel. I do not use a bender. For 1/2 X1" channel or flat bar I bend it cold. I bend it between two short (3" tall) 2.5" sched 40 pipe welded vertically to a plate. Go slow and straighten frequently.

Remember always only make small twist or bend at one time. Realize that it is the sum all the twist or bend that produces the final outcome. Early on you can watch the mill scale when it pop off you know your bending or twisting even if you cannot see it. I also use my thigh or hip to feel the metal move.

Break your rail into sections of about 5-8 feet. If you are using channel on top and bottom then make them fit the stairs then add the cap in longer pieces to lessen the numbers of seams. Once fabricated you can cut it as needed to move it and install it.

You are correct--your trying to keep the rails in parallel planes with the step. One reason a lot of spiral stair kits will have round hand rails because when the helix is made there is no concern about the plane of the hand rail.

Check out www.nomma.org. They sell several educational videos on ironworking. Well worth ordering, especially if your in business.

[CMC Fab]

Thank You Very much for the advice. It is very much appreciated. I will definitely check out the Nomma Site. You wouldn't happen to have any pics of your twisting tool would you?

[tapwelder]

These are over built. They are too heavy to manage when working off the ground. They are curved at the bottom for rocking on the ground.

One is used to hold the material the other tweaks it.

[CMC Fab]

Great tool idea. thank you very much I will let you know my next project turns out. Thank You very much for the pic.