Designer Rail Layout

Laying out aluminium balusters on hardwood and softwood sub-rails, then repeating the layout on the rake of a stair section.

• 01

  Measure the sub-rails separately

  Top and bottom sub-rails are measured and cut separately. They are not assumed to be the same length, because the rail posts may not be plumb.

• 02

  Lay the sections out on the ground

  The sub-rails for each section are laid side by side on the ground, splitting the difference in length where the two are uneven.

• 03

  Mark the centre

  Measure to the exact centre point of the longest sub-rail and make a small pencil mark.

• 04

  Work outwards at 4-3/4 inch centres

  From that centre point, mark every 4-3/4 inches out to both ends. Those marks are the screw positions for the baluster connector, or the centre points for a 3/4 inch hole. The spacing gives a 3-3/4 inch opening once the balusters are in place, which is what keeps the opening under the four inch figure that most building requirements set.

  

• 05

  Set the balusters

  Once the connectors are mounted, or the holes are drilled in softwood, the balusters are placed at their marks.

• 06

  Build the stairs before the rail

  Stair sections, stringers and treads are installed before the rail goes on them.

• 07

  Repeat the layout on the stair sub-rail

  The sub-rails are placed on the stair section and the same measuring sequence is repeated along them.

• 08

  Drill the shallow seat

  Drill a very shallow 3/4 inch diameter hole at 90 degrees at each mark, using a Forstner bit in Ipe or a paddle bit in softwood. Held at 90 degrees, the shallow seat conceals the straight cut end of the baluster on the rake.

• 09

  Mount the connectors and fit

  After the holes are drilled, a connector is mounted in the centre of each one, and the sub-rail is ready to accept the baluster.