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How to replace deck timber handrail?

Hi,

I am replacing my deck old timber railing. The existing system uses a custom-made timber brackets to connect the handrail to the existing posts. I want the new handrail to be cpomposed by a flat 90x19 mm pine timber board on top of a 66x42 with a 19 mm balustrade groove. I am thinking of making the connection to the post with a bracket as shown in the pic. My questions are?

1. What is the best way to conceal the bracket? I am thinking of using the existing balustarde groove and miling a groove on the post. Then I need to cover the post bracket with something before painting on top

2. Is there a better way?

Thanks

Daniel

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Comments

MitchellMc

Hi @danil22,

That's certainly an option and miilling a groove in the post, as you mentioned, would work well. Once the bracket is in place, you can cover it with timber moulding or another thin material before painting for a seamless finish.

If you were going to use a filler, you should recess the bracket into the post by at least 5mm. This will give you enough depth to fill over it with Builder's Bog, ensuring a smooth surface once it's sanded and painted.

Another approach to consider is using a hidden fastening system or dowels. This avoids the need for visible brackets altogether, creating a cleaner look without additional patching. You can also reinforce the handrail by sinking screws through the sides into the post. This will help prevent any twisting or movement over time, ensuring the structure remains secure.

Please let me know fi you have any questions.

Mitchell

danil22

https://www.workshop.bunnings.com.au/discussion/comment/43005#Comment_43005

Thanks!

I can't see how the dowels solution can work. The handrail goes between two posts that can't be moved.

For the builder's bog, will it come off considering it will be placed on metal bracket, not on wood?

Cheers

Dani

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/83619#Comment_83619

Certainly @danil22. If the handrail is between two posts then that method won't work.

You'll need to recess the bracket far enough in that the Builder's Bog can fill the void on top of the bracket. Once it sets inside the void it will stay there. If you only recess the bracket 1mm below the surface the thin layer of bog will likely crack and part ways.

Another thought, depending on the length of the bracket, is to invert it to what you have pictured. That way, the part attached to the post would be hidden behind the end of the handrail itself.

Mitchell

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