Stairgate needs strength...

[Blokky27]

Recess and bond the verticals into pockets in the top and bottom rails. The bigger the contact area, the stronger the joint. Butt jointing like you've done is always going to be weak.

Thank you for the suggestion - it may not be clear from the photo but I used wooden dowels at each end of the verticals to try and strengthen, but they have snapped. I can see how recessing the verticals might help - how do I go about making rectangular recesses that are tight enough to give a good bond and hence strength? Sounds tricky to get the recesses and the dowel holes to all line up perfectly...?

 

[Why Not Indeed]

Dowel centres are perfect for lining up where you want to make holes that line up exactly in opposite faces.
Drill out a round hole and then square it out with a chisel.

 

[Lower]

Thank you for the suggestion - it may not be clear from the photo but I used wooden dowels at each end of the verticals to try and strengthen, but they have snapped. I can see how recessing the verticals might help - how do I go about making rectangular recesses that are tight enough to give a good bond and hence strength? Sounds tricky to get the recesses and the dowel holes to all line up perfectly...?

Lots of different ways to do it.
1. Rout a slot full length down the top and bottom rails. insert and glue your spindles and then glue filler strips between the spindles.
2. Mark out and drill round holes all the way though the bottom rail that you then use as a drill jig for the top rail, then chisel the round holes square.
3. Cross cut full width slots in the top and bottom rails, glue in the spindles and then glue in fillets.

 

[Blokky27]

Thanks all - looks like my bank holiday weekend is now fully booked out!

Will let you know how I get on.

 

[Blokky27]

Lots of different ways to do it.
1. Rout a slot full length down the top and bottom rails. insert and glue your spindles and then glue filler strips between the spindles.
2. Mark out and drill round holes all the way though the bottom rail that you then use as a drill jig for the top rail, then chisel the round holes square.
3. Cross cut full width slots in the top and bottom rails, glue in the spindles and then glue in fillets.

Sounds good - I'm going to go with number 2, along with some metal M6x40 pins instead of wooden dowels. I'm thinking chisel out about 10mm depth?

 

[big-all]

in my humble opinion, the only solution that will add enough strength is first and last spindle and base rail to be welded as one from steel and screwed into the handrail rebate with large tabs
anything else relies on the rigidity off 14 small [compared to length and large leverage]dowels/screws or nails

 

[Lower]

Sounds good - I'm going to go with number 2, along with some metal M6x40 pins instead of wooden dowels. I'm thinking chisel out about 10mm depth?

I'd go as deep as you can. The greater the bonding surface area and the greater the penetration of the verticals into the horizontals, the stronger the assembly will be.