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Drawing 5: BALUSTER INSTALLATION COMPLETE
NOTE: ONCE YOU HAVE BUILT THE BASIC
RAIL SECTION WITH THE TURNED
BALUSTERS, THE REST OF THE
INSTALLATION IS IDENTICAL TO THE
INSTALLATION
LEVEL RAIL MOUNTING HARDWARE KIT
5. INSERT LEVEL RAIL ATTACHMENT
BRACKETS INTO BOTTOM ALUMINUM
STIFFENER
A. Take the U-shaped aluminum stiffener that
you cut for the bottom rail section in step 2C
& slide one of the Level Rail Attachment
Brackets into each end. Slide the long leg of
the bracket into the slot provided in the
aluminum stiffener. (See drawing 6) The legs
of the Ushaped stiffener should point up & the
short leg of the level rail mounting bracket
should also be pointing up.
Drawing 6: U-SHAPED ALUMINUM STIFFENER WITH
LEVEL RAIL MOUNTING BRACKET
6. INSTALL BOTTOM STIFFENER & LEVEL
RAIL ATTACHMENT BRACKETS
NOTE: The rail section will be installed in
between 2 newel posts, walls, columns, full
height posts, or some combination of these
components. For this example, we will
illustrate a rail section being installed between
2 LEVEL RAIL TURNED BALUSTER
2 newel posts (refer to newel installation
instructions).
A. Depending on which rail style & height you
are using, your bottom rail will be either 3½"
or 2¾" above the floor (See Table 1). Cut two
temporary blocks (pieces of 2x4 work well)
the appropriate height & place them next to
each post so you can rest the aluminum
stiffener on top of the blocks. Once resting on
the blocks, check your aluminum stiffener for
level. If it is not level, cut a taller temporary
support block for the end that is low to make
the stiffener level. (See Drawing 7)
Drawing 7: ALUMINUM STIFFENER RESTING ON 2X4
BLOCK
B. Center the aluminum stiffener (with the
inserted brackets) on the face of the newel.
Use a 12" long,
⁄
" diameter twist drill bit
3
16
(also called an "aircraft bit") to drill pilot holes
for the ¼" diameter hex head screws at each
end of the rail. Drill through all 3 holes in the
vertical leg of each mounting bracket.
IMPORTANT: The 12" long bit is necessary
to drill the holes at a shallow angle or
horizontally (See Drawing 8).
Drawing 8: DRILL PILOT HOLES WITH 12" LONG
DRILL BIT
C. Use a drill or impact driver with a 12" long
extension & magnetic driver bit holder & a
3/8" hex driver bit to drive the ¼" hex head
screws into the newel post. (See Drawing 9)
i. IF USING THE HB&G STEEL NEWEL
MOUNT SYSTEM, USE THE 1¼" LONG
HEX HEAD SCREWS.
ii. IF USING A PRESSURE TREATED 4X4
POST FOR YOUR NEWEL SUPPORT OR
ANY OTHER TYPE OF COLUMN OR POST,
USE THE 2" LONG HEX HEAD SCREWS.
Drawing 9: DRIVE HEX HEAD SCREWS INTO NEWEL
POST
D. Remove the temporary 2x4 support blocks
at each end of the aluminum stiffener.
E. Using one of the 4 holes in the long leg of
the rail attachment bracket, you are now
going to drill 1 hole through the aluminum
stiffener at each end of the rail. Any one of the
holes can be used, but the 3rd or 4th hole will
be easiest to use. Take a
⁄
" drill bit & use
9
32
the hole you've chosen in the attachment
bracket as a guide to drill through the
aluminum stiffener. (See Drawing 10)
Drawing 10: DRILL ATTACHMENT BRACKET
MOUNTING-BOLT HOLE THROUGH ALUMINUM
STIFFENER
F. Insert one of the ¼"X ¾" sidewalk bolts
with the large, flat, round head, from
underneath. NOTE: THERE ARE 2 DIFFERENT
LENGTH SIDEWALK BOLTS. IN THIS STEP
FOR THE BOTTOM RAIL SECTION, BE SURE
TO USE THE ¾"-LONG BOLTS. DO NOT USE
THE 1"-LONG BOLTS. Use a stiff putty knife
or the blade of a tri-square (if thin enough) to
prevent the sidewalk bolt from turning as you
tighten a ¼" lock-nut onto the bolt with a
wrench or driver bit. (See Drawings 11A –
11D)
Drawings 11A, 11B, 11C, & 11D: INSTALL
SIDEWALK BOLTS
Tri-square can be used if blade is thin enough or use stiff
putty knife to hold bolt while installing & tightening nut
G. Install the 1¼" square PVC support blocks.
The number of support blocks required will
depend on the length of rail. The maximum
unsupported span is 44". Depending on which
rail style & height you are using, your support
7
⁄
"
16
