How To Convert Your Wood Baluster To Iron. - PDF

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					                How To Convert Your Wood Baluster To Iron.
1.   Remove wood balusters by cutting the baluster in half between the rail and floor with a jigsaw and pulling the
     two ends free. Remaining nails are then pulled and the nail holes filled with matching putty. Sand and
     touchup finish around baluster holes at this time



2.   Measure the distance at each baluster, from the bottom of the rail to the floor surface. Add 1 3/8th inches to
     this measurement to determine baluster length:




3.   To install new iron balusters in existing holes, holes may need to be modified. Using a 5/8 – inch bit, drill in
     the center of existing holes to a maximum depth of 11/16th inches down from floor surface and a minimum
     depth of 1 and ½ inches up into the rail:
4.   The baluster should be cut from the bottom. The top of most balusters have a turned section that allows it to
     be placed in the handrail without the use of a shoe:




5.   Cut the baluster with a metal cutting band saw or jigsaw. If you are doing a small job then a hack saw could
     be used. If you are doing a larger job then consider going to the local rental center and renting a metal
     cutting saw to complete the job.



6.   Balusters should slide up into the rail and down into the floor. Be sure to test your baluster fit before applying
     adhesive. Adjust hole size or baluster length if necessary. Be careful of scrapping the baluster on the floor.
     You can use the 3M painters tape on the bottom of the baluster to protect your floor.



7.   Slide baluster shoes onto the bottom of balusters. The baluster shoes are used to cover old holes and adhesive.
     This is best done after cutting and then using 3M painters tape to hold them up until the epoxy is set.



8.   Install balusters using epoxy or polyurethane adhesive. After “dry” fitting the balusters use the 3M painters
     tape on the baluster just below the handrail to protect against any drips of epoxy.
     9.   Then lower into place the shoes and tighten the set screw for a professional appearance.




Tools needed to complete this job:

     1.   Hammer
     2.   Drill with 5/8” and ½” drill bits.
     3.   Saw (to cut out old wood balusters and a metal cutting saw)
     4.   Epoxy
     5.   3M Blue painters tape




Code issues:
Most areas of the country require that balusters be have no greater than a 4” separation. This is determined by using a
4” sphere or ball. Contact your local code officials to determine what is mandated where you live.

On most stair treads when using iron plan on using 3 balusters per tread and also using 3 per liner foot on balconies and
landings.

Neither Beautiful Homes Inc. nor any of its employees assumes any liability for the installation of products purchased
from us. Instructions are general because every installation will have to be adapted to meet the conditions of your job
site. Use of power tools is inherently dangerous. We assume no liability for use or misuse of any equipment or
products. Always wear eye protection when operating power tools.