Size and source material for handrails

The phosphor bronze wire offered by Tichy Train Group is a very common choice among modelers for forming things like handrails and air piping.  They have a half dozen or so diameters to choose from, and a couple of lengths.  

Two other choices would be brass rod and piano wire.  I believe the brass rod won't be as resilient as the phosphor bronze, for the types of diameters needed.  Piano wire is certainly strong enough, but is hardened, so will potentially require different tools and techniques for cutting and forming.  Neither, as sourced from K&S Metals for example, comes in diameters as small as for the phosphor bronze.  However, they are both offered in .020" and up, so they could work for O scale handrails.

Jim

Edit:  John mentions the hardened cutters for the piano wire.  You can also cut it with a Dremel tool with a cut-off disc.  This also has the advantage of leaving a "square" end to the cut wire, as opposed to a pinched end from diagonal cutters.  However, a few swipes with a file will dress the ends.

I've used both phosphor bronze and piano wire.  I MUCH prefer the phosphor bronze.  It is much easier to cut and bend yet is very resistant to unwanted bending.  Brass wire is way too soft and bends if you look at it.  For new scale handrails, 0.025" is a good size.  I just did some new handrails for an Atlas RS-1 and used 0.040" to match the original steel handrail size.

K&S metals used for handrails.    Stanchions were from Bowser.   

Modular Turntable build.    Similar wire was used for train phone antenna, Weaver E8 models. 

Edit/ADD:   These small round nose pliers worked well for bending wire handrails.  

I also recommend the phosphor bronze product from Tichy Train Group. Like Bob, I keep several sizes on hand to match whatever is already on the model. It’s easy to cut and bend, which helps fine tune the rail to the location. 

Paper clips. Various sizes. Made many grab irons for heavyweight passenger cars and boxcars. Might work for short railings.