Method and apparatus for attaching spindles to rails in a fence assembly

Abstract

A racking assembly for adjustably mounting a spindle to a rail. The racking assembly includes a first member which engages the rail and a second member pivotally secured to the first member. The second member retains the spindle at an angle relative to the first member and therefore relative to the rail. As the second member pivots, the angle of the spindle relative to the rail is changed. In a fence rail assembly, each spindle is secured between a pair of rails by a pair of racking assemblies. Each racking assembly is mounted on one of the rails and is individually adjustable so as to set the angle of the spindle relative to the rails. The rails are secured between a pair of vertical posts. Each rail is secured to one of the posts by a bracket that is adjustable to set the angle of the rail relative to the posts.

1 . A racking assembly for adjustably mounting a spindle on a rail; said racking assembly comprising:
 a first member adapted to engage the rail;   a second member secured to the first member, said second member being adapted to engage the spindle and set the spindle at an angle relative to the first member and therefore relative to the rail; and wherein the second member is adjustably movable on the first member so as to selectively change the angle of the spindle relative to the rail.   
   
   
       2 . The racking assembly as defined in  claim 1 , wherein the second member pivots relative to the first member. 
   
   
       3 . The racking assembly as defined in  claim 2 , wherein the first member has a longitudinal axis adapted to be aligned with a longitudinal axis of the rail and the second member pivots about an axis disposed at right angles to the longitudinal axis of the first member; and wherein the spindle extends outwardly from the second member such that it pivots in a plane coplanar with the longitudinal axis of the first member. 
   
   
       4 . The racking assembly as defined in  claim 2 , wherein the first member comprises:
 a base;   an engagement member extending downwardly and outwardly from a first surface of the base; said engagement member being adapted to be received through an aperture in the rail and to lock the base and rail together.   
   
   
       5 . The racking assembly as defined in  claim 4 , wherein the engagement member includes a pair of opposed flanges that extend downwardly from the first surface of the base, said flanges including a notch that is sized to receive a portion of a rail wall therein. 
   
   
       6 . The racking assembly as defined in  claim 4 , wherein the first member further comprises an exterior wall that extends upwardly and outwardly away from a second surface of the base; and wherein said second member engages said exterior wall and is adjustably movable therealong. 
   
   
       7 . The racking assembly as defined in  claim 6 , wherein the exterior wall includes a substantially semicircular arcuate wall which originates proximate a first side of the base and terminates proximate a second side of the base. 
   
   
       8 . The racking assembly as defined in  claim 7 , wherein the exterior wall further includes:
 a first side wall that originates proximate a third side of the base and terminates in a first arcuate edge with the arcuate wall; and   a second side wall that originates proximate a fourth side of the base and terminates in a second arcuate edge with the arcuate wall.   
   
   
       9 . The racking assembly as defined in  claim 8 , wherein the exterior wall further comprises a lip that extends outwardly from each of the first and second arcuate edges, and wherein said lips have substantially the same radius of curvature as the arcuate wall. 
   
   
       10 . The racking assembly as defined in  claim 9 , wherein each lip originates a first spaced distance from the first side of the base and terminates a second spaced distance from the second side of the base and the first spaced distance is greater than the second spaced distance. 
   
   
       11 . The racking assembly as defined in  claim 7 , wherein the second member comprises a housing having:
 a peripheral wall having a top end and a bottom end;   a bottom wall extending across the bottom end of the peripheral wall; wherein said peripheral and bottom walls define a cavity adapted to receive an end of the spindle therein;   at least one support member extending upwardly from an interior surface of the bottom wall and into said cavity; said support member being adapted to engage the end of the spindle and to retain the same within the second member.   
   
   
       12 . The racking assembly as defined in  claim 11 , wherein the support is spaced a distance inwardly from an interior surface of the peripheral wall whereby a gap is defined therebetween, and wherein the second member is adapted to receive one of the side walls of the spindle in the gap and to clamp the side wall between the support and the peripheral wall. 
   
   
       13 . The racking assembly as defined in  claim 11 , wherein said bottom wall is arcuate in cross-sectional shape and has substantially the same radius of curvature as the arcuate wall of the first member. 
   
   
       14 . The racking assembly as defined in  claim 13 , wherein the bottom wall defines a pair of spaced apart grooves that are configured to interlockingly receive the lips of the arcuate wall therein; whereby the bottom wall is slidingly engaged with the arcuate wall and is positionable at any one of a range of positions on the arcuate wall. 
   
   
       15 . The racking assembly as defined in  claim 11 , wherein the arcuate wall of the first member has a longitudinal axis that is adapted to be aligned with a longitudinal axis of the rail; and wherein the second member is slidably adjustable along the arcuate wall in a direction parallel to the longitudinal axis thereof. 
   
   
       16 . The racking assembly as defined in  claim 15 , wherein the peripheral wall of the second member extends outwardly at an angle relative to the arcuate wall and therefore relative to the base; whereby the second member is adapted to retain the spindle at that angle relative to the base; and when the second member is moved along the arcuate wall of the first member, the angle of the peripheral wall and therefore of the spindle relative to the base is changed. 
   
   
       17 . The racking assembly as defined in  claim 6 , wherein the exterior wall further includes a direction indicator marked thereon. 
   
   
       18 . A fence rail assembly comprising:
 a first and a second vertical post spaced a horizontal distance from each other;   a hand rail and a foot rail connected between said first and second post and spaced a vertical distance from each other;   a plurality of adjustable lower racking assemblies mounted at intervals along said foot rail;   a plurality of adjustable upper racking assemblies mounted at intervals along said hand rail; and   a plurality of spindles; each spindle having a first end that one of the upper racking assemblies; whereby said upper and lower racking assemblies are adjusted to retain the spindles at a desired angle relative to the hand and foot rail.   
   
   
       19 . The fence rail assembly as defined in  claim 18 , wherein the upper and lower racking assemblies are adjustable to retain the spindles at an angle of between 25 degrees and 40 degrees relative to the hand rail and foot rail. 
   
   
       20 . The fence rail assembly as defined in  claim 18 , wherein the upper and lower racking assemblies are adjustable to retain the spindles at an angle of between 25 degrees and 90 degrees relative to the hand rail and foot rail. 
   
   
       21 . The fence rail assembly as defined in  claim 18 , further comprising a plurality of adjustable brackets for connecting the hand and foot rails to the vertical posts; wherein each bracket includes:
 a base that is fixedly secured to one of the posts; and   a rail receiving receptacle movably mounted on the base; and wherein an end of one of the hand and foot rails is engageable in the rail receiving receptacle, and the position of the rail receiving receptacle is adjusted on the base to set the one of the hand and foot rails at a desire angle relative to the post.   
   
   
       22 . A method of assembling a fence rail assembly comprising the steps of:
 securing a plurality of first racking assemblies to a lower rail;   securing a plurality of second racking assemblies to an upper rail;   inserting a first end of one of a plurality of spindles into a spindle engaging mechanism on each of the plurality of first racking assemblies;   adjusting the orientation of each of the spindle engaging mechanisms so as to present the spindles at an angle suitable for a second end of each spindle to be received into a spindle engaging mechanism on one of the plurality of upper racking assemblies; and   adjusting one or more of the spindle engaging mechanisms on the upper and the lower racking assemblies to set the spindles at a desired angle relative to the upper and lower rails.