Getting the cut angles for an opening cap.

When fitting a traditional turned 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.
The stages of cutting an opening cap.

The stages of cutting an opening cap.

Stage 1.
The first stage is to determine the size of cap that suits the handrail profile, this will normally be in the 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 this, draw a circle the size you wish to use and draw the handrail profile centrally over the circle.
Getting the cap size.

Getting the cap size.

Stage 2

Carry the overall width of the handrail down to the circle representing the over all size of the cap.
Transferring the handrail width to the cap.

Transferring the handrail width to the cap.

Stage 3

To get the the inner radius, 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.
Getting the inner cap size.

Getting the inner cap size.

Stage 4

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

Transferring the narrowist part of the handrail to the cap.

Stage 5

Drawing the cut angle.
Once you have all these lines, draw a line from the intersection point of 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.
repaet this on the other side of the cap.
This is the angle at which the cap and ths handrail should be cut.
Drawing the cut angle.

Drawing the cut angle.

Stage 6

Mark these angles onto the opening cap and handrail.
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.
Mark the cap and handrail.

Mark the cap and handrail.

Stage 7

Cut the cap and handrail.
These are now ready for jointing.
Cut the cap and handrail.

Cut the cap and handrail.

Stage 8

That's it job almost done, just one last thing to do
yep you guessed it.
Bolt that sucker up!
Bolt that sucker up.

Bolt that sucker up.

Coming soon
Yep you've all heard that before and yes you will have to wait a week or so until I am next in the workshop but I will do a live demonstration on cutting the opening cap. I will show how to cut the cap on both band saw and chop or drop saw as if on site.
I will add a link here once done.
The opening cap jointed.

The opening cap jointed.