What can you do when you need some modern wooden wall brackets to install a handrail, but you can not find them in stores? You search a lot, get mad, give up looking and start thinking how to find a solution. In a few simple steps, we will show you how our problem was solved. We built these oak wood brackets starting from a simple thin plank.
1. We chose a few boards (oak wood, in this case).
2. We planed them and get them to the needed size: 4 cm wide by 1 cm thick.
3. We cut them to 20 cm length. The idea was to remain 4 cm backup at each end in order to use it to screw the wall brackets onto a board.
4. We glued up the pieces at 90 degrees at the corner, layer by layer. That way, the final bracket will be 4 cm by 4 cm in section. As we said before, we didn’t cut the ends to use them when routing the sharp edges.
5. We sanded all the faces of the brackets, both the outer ones and the inner ones. It’s a process that takes quite a long time, especially when you need a lot of brackets. It’s almost impossible to align the four layers perfectly when tightening them. The differences (which can measure up to 3 mm) are pretty difficult to sand, since oak is a hardwood.
6. We drilled holes into the both ends of each bracket and we screwed them into a scrap piece of panel. We screwed two wall brackets in the same time, in order to easily hold the router.
7. With the brackets hold tight on the table, we started to round the sharp edges using the router with a corner round bit. We couldn’t route the outer corner with the router bit. So we rounded them by sanding using the belt sander.
8. We sanded all the edges using a 120 grit sandpaper.
9. After the sanding process was done, we cut the ends of the wooden wall brackets.
10. In order to easily apply the primer and the varnish, we screwed the wooden brackets onto a large board. That way we were able to apply them on all the brackets at once.
11. After the primer has dried, we sanded with 320 grit sandpaper all the surfaces and we applied the polyurethane varnish.
The wooden wall brackets are ready. They can be used to install almost any type of handrail directly to a wall. They have a simple, yet very nice look.
The corner joint is very strong and the PU adhesive won’t allow for any movement over time. We especially like the grain – end grain joint on the corner of the brackets.