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staircase wall project

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billybuntus

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Hello,

I'm looking to pull out a 60's mahogany balustrade and build a timber frame, overboard then skim and cap with oak for a handrail.

This is to go in a 4 meter span then return onto a wall. My worry is that it may flex? Looking to make it out of 4x2 then overboard with 12.5mm plasterboard. 4x2 screwed to chipboard floor (new floor) Anyone done it before? Any tips to get the best strength? My worry is that it may flex slightly and crack.

I also need to cut off the posts and replace them or trim the existing (warped) posts and overboard.

Just thought I'd ask before I arse it up.

Thanks.
 
Bit difficult to envisage exactly what you propose without a diagram, but it sounds as if you want a standard stair rail, just boxed in - correct? 4m long but 90cm tall? I have built a couple of standard balustrades with railings - the strength comes from the newel post and the floor fixings - can you go for a 4x4 at each end rather than a 4x2? Stair balustrades will generally flex a bit, but if you have a return then you also need a strong corner and your oak cap will either need to be structural, or you need a structural member below it (hidden) so you effectively build a torsion box you then clad in plasterboard and cap.

Another alternative would be to clad in ply or OSB, then plasterboard to minimise flex perhaps?
 
Hello,

That confirms it :-) I find myself over engineering most things with OCD but a torsion box sounds like a good plan. The existing newel is very loose so I plan to pin it in place with wedges and screws. Overboarding with ply/OSB is probably a smart move.

I shall update with progress when I tackle it.

Thanks
 
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