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Got a hand rail job to do and trying to figure out the best way to go about it. See picture:Y axis is existing hand rail coming up steps ending at post (square) on top step. X axis is the rail I have to build on the porch. The porch rail is 9 inches higher than where I need to attach it to the existing post. Would like to see if I can form a spiral to join the two (blue line). What's the best way to approach this?

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Reply:Is there a Z axis an elevation change as well?Sincerely, William McCormickIf I wasn't so.....crazy, I wouldn't try to act normal, and you would be afraid.
Reply:If it changes elevation and you wish to angle both legs of the bend and split the elevation between both legs, the bend is less than 90 degrees. If you use a 90 degree bend and keep one leg level with the world you can just turn or rotate the other leg to fit, and you are done. Sincerely, William McCormickIf I wasn't so.....crazy, I wouldn't try to act normal, and you would be afraid.
Reply:Is it pipe, handrail, box or rectangular tubing? If it is pipe you just need a guy with a pipe roller. You can setup the roller to make a spring out of of pipe at whatever diameter you need to go around your corner. Nine inches in one quarter of a rotation is a lot, it would be pressing the limits of the roller though at such a small radius. You could just roll a 180 degree bend with decent legs and stretch it nine inches in a 90 degree section. If it is standard wrought iron handrail you just need to roll the handrail into a radius that matches the finished piece at the angle the finished piece is on. When you stretch it like a spring the radius or diameter shrinks to the finished size. Because you have a small radius it will be very close to the radius if it was level. Roll more than just the ninety degrees you need. Then just stretch it like you would a spring to create more of a gap between the spring. Then you just cut and weld.

If it is pipe you just roll it to the radius or diameter you need looking at from above, not on an angle. Then just stretch it like a spring.

For city rails that use square or rectangular tube. We just cut flats to the radius of the finished piece, on the angle of the finished product like in the first picture, and just stretch them like a spring. And shear pieces for the sides and just tack and bend them or bend them and tack them. Sincerely, William McCormickIf I wasn't so.....crazy, I wouldn't try to act normal, and you would be afraid.