Forum Discussion
Passin__Through
Mar 05, 2014Explorer
We faced the same problem in our HitchHiker. The stairway walls are (at best) 1/8" thick plywood and I could find nothing in the way of a "stud" or reinforcement of any kind where I needed to anchor a railing. What to do? Being of a rather contrary sort of cuss I tried to live up (or down) to my personal motto - "Illigitimus non carborundum". That being said, or thought, I decided to have at it. The pictures below show the result. So far it has worked well for my wife and I. We were on the road for almost a month last summer, our first long trip with the 5er, and used the railing every day.
Finding a suitable anchor to use in the thin plywood wasn't so difficult. Making it a bit stronger to better support the railing and any loads placed thereon was. Remember, this railing is to maintain balance only. My wife and I know this and use it accordingly.
As you can see in the first picture, I selected the shortest expanding-type Molly anchor I could find. This will grip 1/8" thick plywood very well. The little #6 machine screw that comes with this size is only about .138" in diameter with 32 threads per inch. I elected to drill and tap the anchor to size 8-32 or about .164" in diameter. The anchor body is too small to allow for enlarging to 3/16".

The rail itself was cut from a scrap of 3/4" thick white oak I happened to have lying around the place.

Another view.

I drilled each end to as shown below. The holes are counter-bored to allow the screw heads to be concealed. The holes were used as a drill guide for locating the modified Molly anchors.

Detail of the finger clearance which is about 1".

I sanded and finished the rail prior to mounting it. When the lights are off, it matches the other woodwork perfectly!
Hope this long-winded dissertation is of some benefit. Good luck!:B
Finding a suitable anchor to use in the thin plywood wasn't so difficult. Making it a bit stronger to better support the railing and any loads placed thereon was. Remember, this railing is to maintain balance only. My wife and I know this and use it accordingly.
As you can see in the first picture, I selected the shortest expanding-type Molly anchor I could find. This will grip 1/8" thick plywood very well. The little #6 machine screw that comes with this size is only about .138" in diameter with 32 threads per inch. I elected to drill and tap the anchor to size 8-32 or about .164" in diameter. The anchor body is too small to allow for enlarging to 3/16".

The rail itself was cut from a scrap of 3/4" thick white oak I happened to have lying around the place.

Another view.

I drilled each end to as shown below. The holes are counter-bored to allow the screw heads to be concealed. The holes were used as a drill guide for locating the modified Molly anchors.

Detail of the finger clearance which is about 1".

I sanded and finished the rail prior to mounting it. When the lights are off, it matches the other woodwork perfectly!
Hope this long-winded dissertation is of some benefit. Good luck!:B
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