Once the Design and Selection is complete – How are the balusters installed?

Twenty years ago all iron balusters were solid material, as freight costs skyrocketed and geometric shapes are popular, most all iron is Tubular. Tubular is easier for DIY installation because they need to be cut. Iron Balusters are 44 inches long.

On average there are four (4) lengths required, Balcony, Volute or Start-Step, Front (nose), Middle and Rear of steps. If your staircase has an Angle Wall, the baluster length will be very short (approx. 29 inches). Use a wood Miter Saw for this project by replacing the blade with a Metal Cutting Blade (10 inch). These are available from Stair Solution or a local Big Box or Hardware store for under 10 bucks. Tubular Iron will cut in a few seconds, Solid Iron will take longer. If using Solid Iron we recommend a Band Saw (circular Hack-Saw) or commercial grade cutting equipment. Balusters contain many types of metal, some cut easily and others (stainless steel) take much longer.

Remove Wood Spindles

If this is your first project, we recommend starting with the Balcony area first. Use a JIG SAW to cut the existing wood baluster in the lower portion by the hour-glass shape. Hold the top of the baluster with your other hand while cutting to assure the wood does not drop out of the handrail onto the floor.

There is no standard for how the Builder originally installed the balusters. Some Glue, Glue + Nail, Staple or use really huge nails – just need to work through removing a few to find the best removal process. After the Balusters are removed, check the bottom hole depth and the width/ depth of the handrail hole. Ideally you want the bottom hole no deeper than 1/2 inch and the handrail hole 3/4″-11/16″ width and the hole 1-1/2 inch deep.

Iron Balusters typically have a nipple on the end closest to the ornament. This is not the top of the baluster! Have you ever thought the iron baluster Nipple is the top and always goes up into the hole, but NOT true. The nipple was just a part of the manufacturing process. For the Balcony areas always place the Nipple-Down into the bottom hole. The ornament will end up in the middle of the space between the handrail and bottom – only requires one (1) cut to the longer side of the baluster.

Cut Iron Baluster

Once the wood balusters are removed, measure the distance between the bottom nosing and the underside of the handrail, then add 1-1/2 inches to length. Cut just one baluster, then shoe-horn the baluster into place. If the holes and depth are good – continue cutting. Cut all iron for the Balcony area and install with the Base Shoe.

Apply Adhesive

Use Epoxy with mixing Tip to insert the glue up into the top hole and the bottom including the Base Shoe. Start by gluing the top first for each section of Balusters, than move to the bottom. Be sure to adjust each base shoe to be sure its flush. The Epoxy will dry within 1-3 hours depending on the type used. If epoxy is not available try Loctite's PL adhesive.