29 Aug 21:
We got another order for Alcort Super Sailfish handrails, so we pulled out the tools to cut a new pair. We have not found a local source for cypres yet so we used spruce, it is lightweight and strong, but definitely will benefit from a couple of coats of varnish or epoxy.
We have a pattern for the handrails, and traced out the first pair. While we do have that full size pattern, we only use half of it on one end, then flip it over to mark the other end, which gives us the best symmetry. Spoiler Alert: We missed the knot on the upper right, that would eventually lead to that handrail not being suitable for use on a boat, but we'll find a decorative use for it somewhere.
Better to avoid the knots when tracing out the handrails.
We also cut the rails from a 2x4 and then ripped the 2x4 to get the 3/4 inch width, normally we have 1x dimensional lumber that measures out at 3/4.
Used the pattern to set the rail height.
Another Spoiler Alert: When we got done turning wood into sawdust today we figured out the we can make 4 rails out of a 41 inch long 2x4 by ripping the 2x4 to width and heighth.
Blanks cut to heighth and width.
Used our DeWALT cordless jigsaw to cut out the end curves. It is easier to round over the top edges with the router and 1/8th inch roundover bit at this point, but we forgot and cut out the handrail loops right away. If we round over the top edges first, there is more wood left for the router base to guide over. When it is time to round over the lower edges of the handrail loops, DO NOT round over the base surface of the handrail edges that will touch the deck.
This is what the other half of the 2x4 looked like before we ripped it lengthwise. There would be a benefit to cutting out the handrail loops before ripping, both rails would be symmetrical, and then deal with the router issue.
Along the way we used the RV SUPER POKEY's generator to power the saw and router, as a test, because you never know when you may want to make a set of Sailfish handrails while out camping and entertain your campsite neighbors with the soothing sounds of power tools...
Once everything is cut and the edges rounded, we sand with 120 grit on a DeWALT cordless random orbital sander.
The DeWalt portable table saw and stand has been a great investment. Smooth, clean cuts, easy to set up and it takes up little space in the garage. Also note the patch of shade we had to work in, courtesy of the RV SUPER POKEY's awning. She has LED lighting also, so you can work at night at the campsite :)
Not shown, the last step is to make light pencil marks for the screw holes on the top and bottom of the rails, that gives the buyer a general idea of where screws should go. We can drill the screw holes if requested, but find it best to let the buyer make sure our markings are close to where their boat's screw holes are located.
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