BlueLLama

Found instructions for installing forged balusters on The Wagner Companies site.

Always wear proper safety equipment when cutting, drilling or welding.

The knee wall/stringer must be secure!
This wall will be the base for the balustrade system.

For new installations:

1. Lay out your center marks on the top of the knee wall.
2. Cut and lay out the wooden handrail and lay it on top of the knee wall.
3. Transfer your marks from the knee wall to the handrail.
4. After transferring your marks onto the handrail, drill the correct size holes into the knee wall and into the handrail. Most designs will require that you chisel the holes square in both the knee wall and handrail.
5. Check for fit using a 6″ long piece of the matching bar. Place it into all holes. While the holes in the knee wall should remain extremely tight, the holes in the hand rail should allow the bar to slide in easily. You should also check the angle with a pitch block.
6. Now is the time to begin cutting the balusters. Always allow for a minimum of 1-1/2″ of the vertical bar to be inserted into the knee wall and 1″ to be inserted into the wooden handrail. This should be just a straight cut.
7. Grind all cut ends to allow for a smoother entry into the holes and slide baluster bases into place. Test your fit before proceeding.
8. Apply a small amount of epoxy adhesive into each hole and insert the baluster. Be certain to check each baluster for any slight alignment or adjustments at this time.
9. Continue this same procedure until you have installed all balusters into the knee wall.
10. After all decorative balusters are in place, begin fitting the wooden handrail on top of the decorative ironwork. Apply a small amount of epoxy into each hole when ready for permanent attachment.

Converting existing wood balusters to Iron balusters:

1. Remove the existing wood balusters by cutting each in half between the rail and floor with a saw and pulling the two ends free.
2. Pull remaining nails and fill nail holes with matching putty then sand and touch-up.
3. Modify existing holes to accept iron balusters. Drill 11/16″ down into the floor or knee wall and 1-1/2″ up into the underside of the handrail.
4. Measure the distance at each baluster from the bottom of the rail to the floor surface. Add 1-3/8” to this measurement to determine baluster cut length.
5. Cut balusters to length.
6. Test fit before applying epoxy adhesive and adjust hole size or length as necessary. Balusters should slide up into the rail and then down into the floor.
7. Once you have confirmed fit, remove the baluster and slide baluster bases onto top and bottom of balusters.
8. Apply a small amount of epoxy into the top and bottom holes and then set your baluster into place.
9. Confirm alignment and continue with the balance of your installation.