A level building platform is built before the plan view is set out.
Plan view of stairs. The blue lines represent the inner former mdf molds that the vertical timbers were fixed to.
The inner former is made in two parts in the workshop. The timbers represent the vertical riser lines.
Formers going together on building platform.
Checking for alignment on the two formers. Mistakes made here will cause problems later on.
String shows that as spiral develops, the angle changes and the gap between strings (stringer) gets wider.
Birch veneer is the first layer to be glued over the hardboard
The plywood is grooved so that it bends round the former. On each layer the angle of the groove changes and the board gets wider by about 8mm.
Ply is held in place by clamps and battens.
After 5 layers, banding strips are glued top and bottom to give a hollow core.
Vertical ribs are epoxied between bands.
Outer layers are then glued on, and the surface drawn on. After sanding any lines left will be low spots and so need filling.
A sanding jig is made and the stringer is sanded ,removing the pencil lines.
A 1.5mm birch veneer is glued on, and the radius is checked to be 300mm.
At the same time the inner handrail is glued using the former. This is made up of 16 laminates of 1/4" Ash , cut from one piece of Quarter sawntimber, so that once glued, the glue lines disappear.
A curved jig is made to help cut housing into the stringer for the treads and risers.
The inner work now complete, the outer former is constructed. Each timber represents a rise line, as with the inner former.
The board shows the angle of the outer stringer.
Inside the former.
Boards grooved as before, but this time further apart to help bend the plywood around the former.
Plywood bands being glued in place.
Ribs added and cable passed through for lighting.
Outer handrail being glued on Ash laminates are 3/8" thick and spliced to get the length.
Once 33 sheets of ply have been glued on the outer face is filled and faired, using longboard of correct radius.
Wet sanding gives a smooth surface without any facets.
The outer former is removed and replaced with legs bolted on to outer face.
Selecting the order of the American Oak treads. Each tread made from a 12' board so grain and colour remains good for each tread.
Oak tread wedge.Oak treads were made in the workshop and then each tread was glued up with a riser. All were made the same size.
The outer stringer is housed for treads and risers in a similar fashion to the inner stringer and threaded bar added to keep the stringers in position, like spokes of bicycle wheel.
By using the threaded bar the stringerscould be pushed apart to ease the tread riser pairs into position, starting from the bottom tread.
The stairs were put carefully on its side and taken out of the shed.
wood turbine!
Lowered on to trailer .
En route.
A section of building has been left out to allow the stairs to be craned in.
Stairs taken off trailer and lowered onto field.
In its vertical position it is walked over to the building.
Goes in nicely through gap.
Relief. It fits.
Looking East.
Looking West.
Looking down the stairs .
Looking South
soffit battened out ready for plastering
as the plaster goes on the curves of the sofit become visable
view of stairs,plastered and painted
view from entrance hall
top wreath has tight bend which is achieved by steaming and gluing many thin laminates
wreath joined to outer handrail,ready for final fit
in place ready for fitting to the stainless steel pins
inner handrail wreath being formed over a mold
Inner handrail with wreaths being carved to radiused profile of top face
wreath in place
View with handrail complete
view looking down the stairs
