Metal Saw
As promised I am putting forward information on the installation of iron balusters. During the day, one of the most common questions I get from customers is the how to of iron baluster installation.
Many building codes require three balusters on a tread to comply with the 4″ sphere rule. Check with your local code officials if you have any doubts about your stair’s compliance.
First, I let the customer know that the very last thing in balustrade installation is the iron balusters. It simply works well to install the newel posts, handrail, treads and risers first. Once installed layout the balusters on the floor and use a level to plumb up to the handrail center and mark the connection at the center bottom of the handrail. Using a ½” paddle or spade bit one can drill upward 1″ deep into the handrail. Using a 5/8″ paddle bit drill a hole no more than ¼” deep into the floor. Once these are drilled out the bottom of the handrail can be sanded with an orbital sander and the complete balustrade system can be stained and finished. Once the stain and finish is completed one can begin installing the iron balusters.
One of the following two tools is recommended for cutting iron or metal balusters: a power miter box with a metal cutting blade, or a portable band saw. My preference is the portable band saw. It works cleaner, is more portable, and doesn’t cause sparking as does the power miter box (or chop saw).
Turn the baluster upside down and set the round dowel top into the hole in the floor, holding the baluster plumb to the hole under the handrail. Mark the baluster with a pencil, measure up 3/8″ minimum and that would be the cut mark. Note that you are cutting off the bottom, not the top, of the baluster. This ensures proper alignment of the design elements.
For gluing the installer has two options: Epoxy or construction adhesive. My personal preference is construction adhesive as I have more control over the product and, if it gets messy, wipes away easily and can also serve as a caulk around the iron. Epoxy comes in the mixing tubes and doesn’t always mix properly. If it gets messy and dried, removing the epoxy also removes the powder coating on the iron. Some carpenters prefer and have their own control over epoxy. I do not. I find construction adhesives easier to work with.
Squeeze a small amount of the adhesive into the hole under the handrail. The adhesive is thick and slow and will not drain back out, giving time to complete the installation. Make sure the shoe for the iron baluster is slid up while installing. Push baluster’s round dowel up into the ½” hole under the handrail and then drop it into the 5/8″ hole in the floor in a bed of additional construction adhesive. Square off the baluster’s alignment then drop the shoe down to the floor. If the shoe comes with a set screw, use an Allen wrench to tighten it. The glue in the handrail hole will settle around the baluster creating a perfect seal. Once the glue has dried the baluster will be well secured, even helping to strengthen the handrails load.
When installing 5/8″ iron balusters the process is identical, one only needs to drill a 5/8″ hole under the handrail and a ¾” hole at the floor. 5/8″ iron is ideal in remodeling work, when replacing wood balusters. Most installed wood balusters have a 5/8″ hole under the handrail and a ¾” hole at the floor. If replacing wood balusters with ½” iron it is usually recommended to install shoes under the handrail to cover a small square peg in a larger round hole. The use of wood or cabinet screws helps to lock the baluster in, serving as both a wedge and forcing the baluster on center.
Round 5/8″ iron or metal balusters can be installed without shoes simply by drilling a 5/8″ hole into the handrail and into the floor and following the same procedure outlined above.
I have been asked about making the holes square. It is possible with a little more work. To cut the square hole in the floor or handrail, drill a round hole in the wood the same size at the baluster’s overall width. Then chisel out the hole to make it square. Another option is a “mortising bit.” I have not used one of these but have spoken with carpenters who have. Their comment tends to be that this method is a “pain in the you know what.”
Joseph Swallow has been with Westfire Manufacturing since 1994 and now serves as the company’s CEO. Prior to Westfire, Swallow worked in Southern California and Las Vegas as the primary sales representative for Hardwood Creations, a company which he had founded in his garage in 1981. Westfire Stair Parts are available anywhere in North America and can be purchased by calling Westfire toll free 1.800.692.6996 or by visiting their website http://www.westfiremfg.com.
Evolution Metal Cutting Saw
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IRWIN 373058BX 5/8-Inch Bi-Metal Hole Saw $3.49 |
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RUKO 106160 Bi-Metal Hole Saw 160 mm $96.00 |
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Ruko 106152 Bi-Metal Hole Saw 152 mm $91.89 |
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RUKO 106055 Bi-Metal Hole Saw 55 mm $28.54 |
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Draper Expert 41071 22 mm HSS Bi-Metal Hole Saw Blade $12.57 |
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Rolson 58167 Electrician’s Bi-Metal Hole Saw Kit (9 Pieces) $77.51 |
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Ironside 131001 Metal Saw 300 mm Square $63.86 |
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Irwin Metal and Wood Cutting Sabre Saw Blades (Pack of 25) 10504141 810r $119.74 |
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BOSCH 2608584750 Hole Saw Centring Adapter HSS-Co Sheet Metal L $29.57 |
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Ruko Terrax 126302 Bi-Metal Hole Saw Set CO-5 8-Piece Set $136.86 |
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Wolfcraft 3764000 1 Hole Saw Set 5 Hole Saw Attachments Bi-Metal Plus Hex Adapte $107.57 |
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Silverline 427542 5 Pack 150 mm Bi-Metal Saw Blades $13.71 |
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Silverline 298536 127 mm Bi-Metal Hole Saws $26.09 |
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Irwin 10504157 Sabre Saw Blades Metal and Wood Cutting (Pack of 5) $27.46 |
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Irwin 10504156 Sabre Saw Blades Metal Cutting (Pack of 5) $26.89 |
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Irwin 10504154 Sabre Saw Blades Metal Cutting 624R (Pack of 5) $21.86 |
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Irwin 10504152 Sabre Saw Blades Metal Cutting 614R (Pack of 5) $22.89 |
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Silverline 934114 102 mm Bi-Metal Hole Saw $22.23 |
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Faithfull SBS1118BF Sabre Saw Blades Bi-Metal (Pack of 5) $31.94 |
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Faithfull SBS922BF Sabre Saw Blades – Metal (Pack of 5) $25.03 |
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Faithfull SBS918H Sabre Saw Blades – Metal (Pack of 5) $25.80 |
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Faithfull SBS918E Sabre Saw Blades – Metal (Pack of 5) $27.57 |
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Draper Expert 41069 19 mm HSS Bi-Metal Hole Saw Blade $11.23 |
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Silverline 823540 38 mm Bi-Metal Hole Saw $10.86 |
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Silverline 244966 5 Pack 150 mm Reciprocating Bi-Metal Saw Blade $16.29 |
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Silverline 427630 114 mm Bi-Metal Hole Saw $25.83 |
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Silverline 292711 76 mm Bi-Metal Hole Saws $17.40 |
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Silverline 792094 44 mm Bi-Metal Hole Saw $12.09 |
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Silverline 436754 86 mm Bi-Metal Hole Saw $19.89 |
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Silverline 380657 51 mm Bi-Metal Hole Saw $12.86 |
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Silverline 199882 40 mm Bi-Metal Hole Saw $10.97 |
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Silverline 704409 70 mm Bi-Metal Hole Saw $17.29 |
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Silverline 801291 152 mm Bi-Metal Hole Saws $29.43 |
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Silverline 282507 108 mm Bi-Metal Hole Saw $21.66 |
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Silverline 427588 350 mm All-Metal General Purpose Saw $16.23 |
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Draper Expert 02306 200 mm 6-Teeth-Per-Inch Bi-Metal Reciprocating Saw Blades fo $52.60 |
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Draper Expert 02305 150mm 6-Teeth-Per-Inch Bi-Metal Reciprocating Saw Blades for $43.43 |
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Draper Expert 02307 250 mm 6-Teeth-Per-Inch Bi-Metal Reciprocating Saw Blades fo $63.00 |
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Draper Expert 02308 300 mm 6-Teeth-Per-Inch Bi-Metal Reciprocating Saw Blades fo $66.40 |
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Draper 02302 Expert 150mm 10 Teeth Per inch Bi-Metal Reciprocating Saw Blades fo $23.94 |
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Draper 02301 Expert 250mm 6 Teeth Per inch Bi-Metal Reciprocating Saw Blades for $37.00 |
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Irwin 10504159 Sabre Saw Blades Metal and Wood Cutting (Pack of 5) $38.71 |
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Irwin 10504151 Sabre Saw Blades Metal and Wood Cutting (Pack of 5) $21.74 |
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New Professional Dewalt Set D180004 Bi-Metal Finish Saw Door Lock Installation. $49.99 |
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LENOX 1-1/8″/29mm BI-METAL HOLE SAW 30018-18L NEW! $15.00 |
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Wolfcraft 5474000 Hole Saw Bi-Metal with Hex Shaft and Drill Bit Ø 68 $32.63 |
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Draper 02303 Expert 200mm 10 Teeth Per inch Bi-Metal Reciprocating Saw Blades fo $32.86 |
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Faithfull 24TPI Coping Saw Blades Metal (Pack of 10, 10 Sleeves each) $66.57 |
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Dremel Saw-Max DSM20 Metal Cutting Wheel (3pk) $22.57 |
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Silverline 349763 32 mm Bi-Metal Hole Saw $9.86 |
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Silverline 273220 Electrician’s Bi-Metal Hole Saw Kit $41.51 |
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LENOX 7/8″/22mm BI-METAL HOLE SAW 30011-14L NEW! $15.00 |
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METAL FAB 3″ 6″TEMP/GUARD INCREASER CORN/PELLET 3P6SAW $38.00 |
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Starrett DH1036 21mm 13/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $17.09 |
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Starrett DH0034 19mm 3/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $17.09 |
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Starrett DH2532 20mm 25/32-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $17.09 |
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Starrett DH0100 25mm 1-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $21.91 |
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Starrett DH1016 17mm 11/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $17.09 |
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Starrett DH0118 29mm 1.1/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $24.29 |
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Starrett DH0096 14mm 9/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $21.51 |
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Starrett DH0334 95mm 3.3/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $48.80 |
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Starrett DH0278 73mm 2.7/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $37.80 |
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Starrett DH0138 35mm 1.3/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $27.86 |
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Starrett DH0318 79mm 3.1/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $39.34 |
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Starrett DH0438 111mm 4.3/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $77.94 |
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Starrett DH0312 89mm 3.1/2-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $43.57 |
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Starrett DH0216 52mm 2.1/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $32.71 |
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Starrett DH68mm 68mm 2.11/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $36.91 |
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Starrett DH1136 46mm 1.13/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $31.46 |
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Starrett DH0078 22mm 7/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $17.86 |
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Starrett DH0512 140mm 5.1/2-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $119.00 |
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Starrett DH0338 86mm 3.3/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $42.14 |
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Starrett DH0158 41mm 1.5/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $30.29 |
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Starrett DH210mm 210mm 8.9/32-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $281.17 |
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Starrett DH0238 60mm 2.3/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $35.86 |
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Starrett DH0200 51mm 2-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $31.46 |
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Starrett DH0296 65mm 2.9/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $36.29 |
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Starrett DH0134 44mm 1.3/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $31.46 |
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Starrett DH0218 54mm 2.1/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $33.71 |
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Starrett DH0600 152mm 6-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $135.54 |
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Starrett DH0258 67mm 2.5/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $36.89 |
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Starrett DH0196 40mm 1.9/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $30.03 |
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Starrett DH0514 133mm 5.1/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $112.71 |
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Starrett DH0178 48mm 1.7/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $31.46 |
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Starrett DH0314 83mm 3.1/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $40.80 |
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Starrett DH160mm 160mm 6.5/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $227.31 |
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Starrett DH1116 43mm 1.11/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $31.46 |
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Starrett DH0114 32mm 1.1/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $25.51 |
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Starrett DH0412 114mm 4.1/2-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $80.14 |
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Starrett DH0156 33mm 1.5/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $25.57 |
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Starrett DH0418 105mm 4.1/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $57.34 |
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Starrett DH1056 24mm 15/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $19.14 |
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Starrett DH0176 37mm 1.7/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $27.86 |
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Starrett DH0358 92mm 3.5/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $44.71 |
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Starrett DH0434 121mm 4.3/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $92.94 |
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Starrett DH0414 108mm 4.1/4-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $70.94 |
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Starrett DH0378 98mm 3.7/8-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $51.97 |
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Starrett DH56mm 56mm 2.3/16-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $34.71 |
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Starrett DH0112 38mm 1.1/2-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $29.31 |
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Starrett DH0500 127mm 5-inch HSS Bi-Metal Dual Pitch Professional Hole Saw $105.34 |
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Ginsu 7108 Chikara 8-Piece Stainless-Steel Knife Set with Bamboo Block $119.99 8 Pc Bamboo Block Set… |
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Amco Swing-A-Way 407RD Portable Can Opener, Red $5.29 Amco Houseworks 407RD Swing-A-Way Portable Can Opener Red… |
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EdgeCraft 610 Chef’s Choice Premium Electric Food Slicer $119.95 610 Premium Electric Slicer… |
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Jackyl $7.04 All products are BRAND NEW and factory sealed. Fast shipping and 100% Satisfaction Guaranteed…. |
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Selected Ambient Works Volume 2 $18.96 British electronics wunderkind Richard James (alias Aphex Twin, AFX, Polygon Window, etc.) claims he heard the compositions on Selected Ambient Works, Volume II in lucid dreams. Like abstract paintings composed of shades of a single color, James’s resonant explorations of specific timbres linger close to a central idea on each cut, incorporating just enough variation to remain disturbing. While it… |
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Stanley Consumer Storage 020800R FatMax 4-in1 Mobile Work Station for Tools and Parts $79.97 The Stanley 020800R FatMax Four-in-One Mobile Work Station offers versatility to professionals who need to stay organized when transporting tools and materials to and from jobsites. This mobile work station is a cantilever-style multilevel unit that allows for full access to all your tools. It comes equipped with a tool box, tray, organizer, and large bottom bin, making it ideal for plumbers, elec… |
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Tripp Lite PV150 PV 150W 12V DC to AC Portable Inverter with DC Auto Power Outlet $22.91 300 watts peak150 watts continuous power Low-battery alarm with auto-shut-off prevents deep battery dischargeLightweight design with all-metal housingClean quiet operation1 AC outlets 3 3/4″W x 1 3/4″H x 5 3/4″DPV-375: 4 1/4″W x 2″H x 7″DPV-600 6 1/4W x 4″H x 10 1/4″DIncludes DC cigarette lighter plug… |
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Tripp Lite PV3000HF PV 3000W 12V DC to AC Permanent Mount Inverter $388.50 Harness your vehicle”s battery to efficiently power office equipment on the road or power tools at a work site. Continuously supplies up to 3000 watts of 120V AC power to 4 AC outlets from any 12V battery or automotive DC source. Includes a PV remote and 25 feet of cable. Super-compact, lightweight metal case design is among the smallest, most rugged inverters available at this power level…. |
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Victorinox Swiss Army Champion Plus Pocket Knife $34.99 From the renowned company that created the Swiss Army Knife a century ago comes the Champion Plus, a complete set of tools for campers, hikers, hunters, fishers, picnic enthusiasts, and people all trades–all neatly contained in a single implement. Measuring just 3-1/2 inches long, the Champion Plus is stylishly cased in the famous red Swiss Army body that’s recognized around the world. More impor… |
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