Methods and tooling for constructing a stair unit are provided. The methods incorporate tooling and tables to create templates (two for each tread) that, when laid along a series of hypotenuse marks on the stringer from the table, will dictate the geometry, cutting, and fitting to the treads, withou
Methods and tooling for constructing a stair unit are provided. The methods incorporate tooling and tables to create templates (two for each tread) that, when laid along a series of hypotenuse marks on the stringer from the table, will dictate the geometry, cutting, and fitting to the treads, without using a framing square. Brackets are used to conjoin the stringer, tread material, and tread framing so that the tread width is not limited by the lack of strength of the tread material. The methods then incorporate the bracket in a tread module to provide further convenience and sequencing options for the assembly of the stair unit. An alternate method combines aspects of the template and the bracket to hold continuous support for the tread, accomplishing a cut stringer look. The result is less time and material expense with better strength, fit and finish.
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1. A method for constructing a stair unit, comprising: determining a number of treads and a rise and run of each tread;determining a first angle (“horizontal angle”), a second angle (“vertical angle”) and a hypotenuse of a right template triangle, the template triangle having a first side (“horizont
1. A method for constructing a stair unit, comprising: determining a number of treads and a rise and run of each tread;determining a first angle (“horizontal angle”), a second angle (“vertical angle”) and a hypotenuse of a right template triangle, the template triangle having a first side (“horizontal side”) with a length equal to the run, a second side (“vertical side”) with a length equal to the rise, the horizontal angle being the angle between the first side and the hypotenuse and the vertical angle being the angle between the second side and the hypotenuse;cutting a pair of template triangles for each tread;securing a first of each pair of template triangles to an inside surface of a first stringer with the hypotenuse of each template triangle parallel to and even with an upper edge of the first stringer and in line with the hypotenuse of an adjacent template triangle;securing a second of each pair of template triangles to an inside surface of a second stringer with the hypotenuse of each template triangle parallel to and even with an upper edge of the second stringer and in line with the hypotenuse of an adjacent template triangle;cutting a top end of both stringers whereby a back edge of each stringer will be parallel to a perimeter joist to which the stair unit is attachable;cutting a bottom end of both stringers whereby a front edge of each stringer is be parallel to the back edge and a bottom edge of the bottom end is perpendicular to the front edge and substantially parallel to a lower landing surface; andsecuring a plurality of tread modules between the stringers, each tread module being in a one-to-one relationship with a corresponding pair of template triangles, a top surface of a tread plank of each tread module abutting a bottom edge of the horizontal side of the pair of template triangles, thereby forming the stair unit. 2. The method of claim 1, wherein cutting the template triangle comprises cutting a notch configured to receive an overhang by the tread plank. 3. The method of claim 2, wherein: the vertical angle in degrees equals arctan (run/rise);the horizontal angle in degrees equals 90-vertical angle; andthe hypotenuse equals [1/sin(vertical angle)]*(run). 4. The method of claim 1, further comprising: constructing each of the plurality of tread modules by: securing a first of a pair of brackets across bottom surfaces of first and second tread planks at a first end of the tread planks and securing a second of the pair of brackets across the bottom surfaces of the first and second tread planks at a second end of the tread planks;placing first ends of front and rear joists into a corresponding pair of U-shaped openings of the first of the pair of brackets and placing second ends of the front and rear joists into a pair of corresponding U-shaped openings of the second of the pair of brackets; andsecuring the first ends of the two joists to the first of the pair of brackets and securing the second ends of the two joists to the second of the pair of brackets; andsecuring the plurality of tread modules between the stringers by securing the first bracket to the inside of the first stringer and securing the second bracket to the inside of the second stringer, whereby the front and rear joists extend between the inside surfaces of the two stringers. 5. The method of claim 4, further comprising: forming facing cutouts in the tread planks;passing a handrail post through the cutouts in the tread planks and through a notch in the first of the pair of brackets;securing the handrail post to the stringer through the first of the pair of brackets beneath the tread planks; andfurther securing the handrail post to the stringer through the template triangle above the tread planks. 6. A method for constructing a stair unit, comprising: determining a number of treads and a rise and run of each tread;determining a first angle (“horizontal angle”), a second angle (“vertical angle”) and a hypotenuse of a right triangle (“structural triangle”), the template triangle having a first side (“horizontal side”) with a length equal to the run, a second side (“vertical side”) with a length equal to the rise, the horizontal angle being the angle between the first side and the hypotenuse and the vertical angle being the angle between the second side and the hypotenuse;cutting a pair of structural triangles for each tread;cutting a notch in the vertical side of each structural triangle configured to receive a joist;securing a first of each pair of structural triangles to a top edge surface of a first stringer with the hypotenuse of each structural triangle against an upper edge of the first stringer and in line with the hypotenuse of an adjacent structural triangle;securing a second of each pair of structural triangles to a top edge surface of a second stringer with the hypotenuse of each structural triangle against an upper edge of the second stringer and in line with the hypotenuse of an adjacent structural triangle;cutting a top end of both stringers whereby a back edge of each stringer will be parallel to a perimeter joist to which the stair unit is attachable;cutting a bottom end of both stringers whereby a front edge of each stringer is be parallel to the back edge and a bottom edge of the bottom end is perpendicular to the front edge and substantially parallel to a lower landing surface; andsecuring a set of front joists within the cut notches and extending between each set of opposing structural triangles on the stringers;securing a set of rear joists between the inside surfaces of each set of opposing structural triangles on the stringers; andsecuring a tread plank to tops of each pair of front and rear joists. 7. The method of claim 6, wherein: the vertical angle in degrees equals arctan (run/rise);the horizontal angle in degrees equals 90-vertical angle; andthe hypotenuse equals [1/sin(vertical angle)]*(run).
Cappel Walter H. (1523 20th Ave. N. Texas City TX 77590) Hartenberger Gerald W. (3010 Layne LaPorte TX 77571), Interlocking shelf bracket for a firewood rack or similar article.
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