Almost Completed Rail [9/28/05]

I was thinking about how to fix the rail so that it won't gouge out your base and was wondering if anyone had any experience with this or any suggestions. I was thinking about filling down the sharp edge on the coping and putting a 2x4 flat against the end and filing that to a curve with a 1.5" radius. Do you think this will be sufficient or have any other suggestions? Thanks.


Also feel free to use this thread to post any other questions anyone has about building rails/boxes.

If you have the tools and materials. Add a front to it like a battleship would have. Cut your 4x4 end at a 45 degree angle and throw copping on the sides. Line it up and file it down nicely. That way if you miss the rail will push you up anyways. If you have welding stuff weld the connection and file it down, otherwise, just do your best not to leave a gap.

put a piece of pvc in the front. On metal rails you take a two inch of piece of of round steel (assuming you have a 2x4 metal tubing) and weld pieces to both ends and shape them and grind them. If you could shape it some how where the pvc in into the wood a little bit. It could be the same principal.
Oh and is that just angle iron around the wood? Are you putting plexi in there cuz if not there is that slim chance you might get your bases or edges in to the wood possibly, cuz you board bends a lot.

i dont think that you have to worry about plexi, its skinny enough that with those angle irons your board wont get hung up on the wood

The PVC sounds like a good and easy fix. It is only angle iron, but it is only 1.5" wide. Thanks for the Ideas. I'll post pics when i'm done.

[edit] the quick edit is realy cool. [/edit]