How to join 2 pieces of 1-5/8 round handrail? Make a seamless joint.?

Question

I need to extend the handrail on my front stairs. I'm using 1-5/8 round Douglas Fir. I need to create a butt joint between the existing rail and my new section. Each time I try to create the joint the new piece doesn't look continuous. The joint doesn't match up properly. I'm trying to blind drill a hole so I can use a dowel to support the joint. Any tips or tricks to make this joint work properly?

Answer 1

measure center where you would put the dowel, try on test pieces first

Answer 2

Best way would to remove the railing.

Using a combination square with a centerfinder attachment mark the center of the railing and the center of the add on.

Then drill your holes for the doweling(drill the holes a little deep)

Next lay the two end to end and lightly pencil a straight line down the railing across the joint and onto the addition(you should go a little long each way for the next step) This is simply an alignment mark.

Now set the two pieces up on a mitre saw keeping the two aligned and make a miter across the joint. You may have to make several cuts to bring the two together correctly. The mitre cut will allow for more surface area for gluing.

Answer 3

What you need to do is to measure the centers on the 2 pieces exactly.Which is tricky bc of the shape but with care it can be done.And dont use a dowel to join them Get one of those specialty screws that has threads facing both ways.You're never going to get the seam to disappear.But take your time and get the pieces lined up flush or within 1/64 " of flush and with a light sanding you'll make the seam just barely visible.