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blocks will need to be either 3½" or 2¾"
high (see Table 1). The blocks that come with
the kit are 3½" long. If your rail requires 2¾"
long support blocks, cut the 3½" blocks to
that length.
i. 6' rail = 1 support block
ii. 8' rail = 2 support blocks
iii. 10' rail = 2 support blocks
iv. 12' rail = 3 support blocks
Determine the location of the support blocks.
Take the PVC rail section you assembled
(shown in Drawing 5) & hold it in place so
you can locate the support blocks directly
under balusters in the rail section. After
marking the support block locations, set the
rail section aside & drill a hole through the
center of the aluminum stiffener with a
drill bit at each of the support block
locations. Do not drill into the support blocks.
After drilling the holes for each support
block, place the support blocks in position &
while grasping the support block with one
hand, drive a #8 X 2½" long stainless steel
flat head screw directly into the center of
each support block. (See Drawings 12A &
12B)
Drawings 12A & 12B: INSTALL SUPPORT BLOCKS
7. INSERT & INSTALL ASSEMBLED PVC
RAIL SECTION
A. Now you are ready to insert & snap into
place the PVC rail section you pre-assembled
in steps 1-4. Verify that the length of the top
& bottom PVC rails are the correct length to
fit closely between the support components
(newels, columns, posts, or wall) NOTE: Be
sure the decorative newel caps are
removed for easier installation of the rail
section. Take the pre-assembled rail section
& tilt it at a slight angle as you slide the
bottom PVC rail into place & hook it over the
bottom aluminum stiffener. (See Drawings
13A & 13B)
Drawings 13A & 13B: TILT PRE-ASSEMBLED
RAIL SECTION & SLIDE INTO PLACE
B. Continue tilting the rail section into place
until it is vertical. After the rail section is
vertical, press firmly on the top rail to snap the
bottom rail into place over the bottom aluminum
stiffener. (See Drawings 14A & 14B)
Drawings 14A & 14B: RAIL SECTION TILTED INTO
VERTICAL POSITION. BOTTOM PVC RAIL FULLY
SNAPPED INTO PLACE OVER BOTTOM ALUMINUM
STIFFENER
3
/
"
16
Bottom PVC rail snapped into place over bottom
aluminum stiffener
C. Take top rail aluminum stiffener that you
cut to length in step 2C & slide the remaining
2 Level Rail attachment brackets into each
end. (See Drawing 15)
Drawing 15: TOP ALUMINUM STIFFENER WITH
LEVEL RAIL MOUNTING BRACKETS
D. Drop the top aluminum stiffener into the
space between the legs of the upper PVC rail.
Before doing that, note whether the baluster
screws in the PVC rail are to the left or right
of center over the balusters. Once the
aluminum stiffener is in position, snap it down
into place so the top edges of the legs of the
aluminum stiffener are even with the top edges
of the legs of the PVC rail. NOTE: The small
ridges on the outside faces of the aluminum
stiffener legs running the length of the
stiffener should snap into the shallow
grooves running the length of the PVC rail,
on the inside faces of the PVC rail legs. (See
Drawings 16A,16B & 16C)
Drawing 16A: DROP TOP ALUMINUM STIFFENER INTO
PLACE
Drawing 16B: DROP TOP
Drawing 16C: SNAP TOP
ALUMINUM STIFFENER
ALUMINUM STIFFENER
INTO PLACE
INTO PVC RAIL
E. Center the aluminum stiffener (with the
inserted brackets) on the face of the newel. Use
a 12" long,
⁄
" diameter twist drill bit (also
3
16
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
17A).
F. Use a drill or impact driver with a 12" long
extension & magnetic driver bit holder & a
hex driver bit to drive the ¼" hex head screws
into the newel post. (See Drawing 17B)
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.
LEVEL RAIL TURNED BALUSTER 3
/
"
3
8
