Surrey Carpentry

Professional Carpentry & Joinery Service

Another nice job in West Byfleet this week, i’ve been fitting the oak nosing that goes underneath the curved gallery ballustrading on the first floor of the house.

Here the curved sections of the oak nosing have already been fitted. 18mm of ply facing had to be cut down to take it as well as chiseling out some of the screed.

Here the curved sections of the oak nosing have already been fitted. 18mm of ply facing had to be cut down to take it as well as chiseling out some of the screed.

Once the nosings were fixed in place, the oak balustrading which had already been fabricated at Mayford Joinery could be positioned and fixed into place above  the nosing.

Once the nosings were fixed in place, the oak balustrading which had already been fabricated at Mayford Joinery could be positioned and fixed into place above the nosing.

Here some batons have been fixed to the facing. If you put a spirit level on the batons, they show as plumb, unlike the facing they are fixed to

Here some batons have been fixed to the facing. If you put a spirit level on the batons, they show as plumb, unlike the facing they are fixed to

The nosing could only be fixed on once 18mm of ply facing was cut by the thickness of the nosing, and there was some screed that needed chiseling out too. The curve of the oak nosings and the curve of the ply facing were completely different. I had to position the nosing about 25mm proud of the ply facing in some areas, in order for the apron to be able to slot up into the groove in the nosing.

Once the curved nosing  sections were fixed on, it was pretty straightforward to fit the straight sections in between the curved sections, and between the curved sections and the newels at either end.

Once all the sections of the nosings were fixed in place, the pre-fabricated curved balustrading could be positioned and fixed above the nosing. Mayford Joinery did a great job putting this balustrading together.

With the nosing in place, the next job was to mark down from the groove on the underside of the nosing, measuring how thick the batons that would be fixed to the ply facing would need to be. This was a pretty laborious job, as the ply was kinked and warping all over the place. I had to mark where each 25mm baton would go, being spaced 50mm apart, and then use a spirit level to project down from the rear side of the nosing groove and measuring the gap between the level and the ply facing at the top and bottom facing to work out how thick each baton would have to be at each end.

Batons were fixed on with a screw at the top and the bottom.

Batons were fixed on with a screw at the top and the bottom.

More batons fixed on

More batons fixed on

All batons now fixed on

All batons now fixed on

Conrad at Mayford Joinery very kindly let me mark out and cut all 74 batons at his workshop using the bandsaw. I have to say that without a bandsaw, this part of the job would have been a bit of a nightmare, and wouldn’t have been that accurate!

With all the batons tapered and numbered, it was pretty easy to fix them onto the facing, actually it was quite therapeutic!

The next job was to cut the mdf apron to size. We used a sheet of 6mm mdf with one side having been kerf-cut, allowing the mdf to bend very easily while keeping the face side very smooth for when it will be painted.

The measurement from in the groove of the oak nosing to the ceiling below was about 415mm so i cut two 420mm strips of bendy mdf, one to go into each of  the curved sections of the gallery.

Once cut, the 8' length of bendy mdf was pretty unwieldy, so i had to use a sash cramp to hold it in place. My aim here is to slot the 6mm mdf up into the 6mm groove in the oak nosing before pinning it to the batons.

Once cut, the 8

After a few minutes of trying to persuade the apron into the groove, it was becoming clear it waqs going to take more than two hands and a sash cramp to get it in it's groove, so my client jumped up and gave me a hand and we got it sorted. He took this photo too, nice guy!

After a few minutes of trying to persuade the apron into the groove, it was becoming clear it was going to take more than two hands and a sash cramp to get it in it

First section of the bendy mdf is fixed on. We did the same on the other curve. Once they were both fixed, i then just had to cut 420mm x 1232mm peice of regular 6mm mdf onto the straight section between the two curves. All that was required to fix them on was a single course of pins along the bottom edge of the apron and along the sectional joins. Where the joins met, i added an additional baton to the facing that both joining edges of the mdf could be fixed to.

First section of the bendy mdf is fixed on. We did the same on the other curve. Once they were both fixed, i then just had to cut 420mm x 1232mm peice of regular 6mm mdf onto the straight section between the two curves. Because the top edge was secured by the groove, all that was required to fix them on was a single course of pins along the bottom edge of the apron and along the sectional joins. Where the joins met, i added an additional baton to the facing that both joining edges of the mdf could be fixed to.

Once all the sections of 6mm mdf apron were fixed on, the next job was to tidy up the bottom edge, by taking off 5 or 6mm to match it to the ceiling line. This was more difficult than you might think due to the kerf-cut mdf. If i planed it, it would have broken off the kerf cuts on the back of the apron before they had become short enough not to obstruct the cover bead that would later be fitted. So i marked the ceiling line onto the mdf using a very sophisticated peice of notched out baton, placed the notch over the apron excess and slid the baton along the ceiling behind the aprons excess and used the remaining end of un-notched baton as a scribe to run my pencil along, giving me the perfect ceiling line. I then belt-sanded the apron excess up to the line.

With the apron now flush to the ceiling, the next job was to make the cover beads for the underneath of the apron.

The 35mm wide cover bead was made using 6mm mdf. The straight sections were very straight-forward and use very little material, but when it comes to the curved sections, you need to make sure you have enough material! You cant bend a straight section, you have to cut it to the radius you need, and for two curved sections of 35mm bead, you'll need nearly a whole 8' x 4' sheet of mdf

The 35mm wide cover bead was made using 6mm mdf. The straight sections were very straight-forward and use very little material, but when it comes to the curved sections, you need to make sure you have enough material! You cant bend a straight section, you have to cut it to the radius you need, and for two curved sections of 35mm bead, you

I made the curved sections of the cover bead using a router. I basically used it like an over grown pair or compasses. I cut a peice of mdf long enough to fix my router to and measure from the cutter along to the point of my radius. I then screwed through the pivot point and made sure that enought material was under the cutter of my router when i moved it along the circumference of the circle.

I made the curved sections of the cover bead using a router. I basically used it like an over grown pair or compasses. I cut a peice of mdf long enough to fix my router to and measure from the cutter along to the point of my radius. I then screwed through the pivot point and made sure that enought material was under the cutter of my router when i moved it along the circumference of the circle.

Here are the finished curved beads. I also routed a 4mm radius detail onto the edges of all the sections of bead. Quite a lot of work for something so small!

Here are the finished curved beads. I also routed a 4mm radius detail onto the edges of all the sections of bead. Quite a lot of work for something so small!

Once the routing was done, i then cut the curved beads to the right length and fixed them underneath the apron by pinning them to the same batons the apron is pinned to. Once they were on, i then cut the straight sections between the curves and the newels.

Job Done!

Me just about to pack up at the end of a produdtive day!

Me just about to pack up at the end of a productive day!

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