Pipe rail jig

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I have 150 feet of pipe rail to build.  I have done several pipe jobs before, however this job has 9 pitched (30 degrees) handrails on steps.  Since all are the same same pitch only varying lengths, I wanted to make a jig.  I usually only use spacers and a triangle made of channel to build each individual rail.  I also usually build them laying on a table. Does anybody have suggestions on making a jig for setting up pipe rail with a pitch?  The rails will be of 3 rail construction with no balusters.  The length are 120, 67,54 inches.  I am using 1.25 schedule 40 pipe.
Reply:There really isn't a problem.  You just build it on your table but make yourself a large bevel gauge.  Most railing tables have an angle iron running the length on the far edge.  I am guessing yours does also.  If not tack one on.  You know the spacing of the stanchions/posts so lay that out on your top rail then set the rail against the angle backstop.   I just set the first post fishmouthed at the correct angle on the mark and adjust it to the angle.  Thirty degrees in your case?
Reply:The trick to this is what you use for a large bevel gauge.  I have a large power hacksaw blade about 18 inches long hinged in a piece of oak .  I can set the angle with this large gauge and use it to adjust my post angle.  Some guys use a couple of angle around one and a half by one and a half hinged.  If you rig the hinge using a bolt and nut you can tighten it to lock the angle and the legs of your angles will sit flat on the table.  If your top post is always fitted the same way you can tack weld tabs to locate it and just worry about the post or posts further along the railing.  I prefer a wooden table for railing production using headless nails for laying out a template/jig.  It is delicate but fast and the spatter when tacking burns into the wood.  The table has to be heavy... steel frame, 2X8s covered with 3/4 plywood sheets.   Most shops use a steel table.
Reply:Here is a pic of my large home made bevel gauge. Attached Images
Reply:I just lay it out on the table and tack down some stops. If the angles are all the same, all you have to do is cut and set. Here is how I did one for a small job. There was about a four inch slope on these. I just laid it out accordingly. Attached Images
Reply:Thanks for the info. guys.The wood idea really sounds tempting for tacking.  It would keep my tables free.  Definately have to build it outside because on smell.  Bolt tabs on like DDA52.  Last time I made a pipe rail I made a 30-60-90 triangle from channel.  The channel was welded flange side out.  At a 30 degree pitch I could slide the triangle into the appropiate angle and clamp two pieces to together.  The 90 degree works for the end. I was proud of that design.  There are natural notch at each vertex so the triangle does not interfere with welding.
Reply:The wooden table/surface is only for full production.  The wood does not catch on fire.  In fact in that shop they just put another layer of plywood on every couple of years.  The fresh ply was slightly burned with a torch so that the chalk lines would stand out.  If you make an angle or channel bevel hinged you can hang it on the wall between uses and save time making up an angle template each time the same type of job is encountered.
Reply:Ol' Bill made this---- serves well.                        Sorry bout pics,can do better if you want............Tim Attached Images
Reply:TekOn the first picture what is happening at the bottom edge of the table?  Looks like a vice clamp attaching it to the table. Are all three flat bars attached with one bolt? What is the bent round bar?Thanks
Reply:tapwelder---The two pieces are bolted together and the round is just to hand tighten the bolt. The visegrips are to help hold it on the set degree. I'll get better pics tomorrow if it'll help.
Reply:Originally Posted by tapwelderI have 150 feet of pipe rail to build.  I have done several pipe jobs before, however this job has 9 pitched (30 degrees) handrails on steps.  Since all are the same same pitch only varying lengths, I wanted to make a jig.  I usually only use spacers and a triangle made of channel to build each individual rail.  I also usually build them laying on a table. Does anybody have suggestions on making a jig for setting up pipe rail with a pitch?  The rails will be of 3 rail construction with no balusters.  The length are 120, 67,54 inches.  I am using 1.25 schedule 40 pipe.
Reply:Better pics of the angling device tool thingamabob Attached Images