Converting your balustrade from wood to iron balusters
This is a step-by-step procedure for removing existing wood
balusters and replacing them with iron balusters without removing handrails and
newels
Removing
Existing Wood Balusters
Removing
wood balusters is easily accomplished by cutting the baluster in half
between the rail and floor with a jigsaw and pulling the two ends free
Remaining
nails are then pulled and the nail holes filled with matching putty
Sand
and touchup finish around baluster holes at this time
Installing New Iron Balusters
To install new iron balusters in existing holes, holes may
need to be modified. Using a 5/8 – inch bit, drill in
the center of existing holes to a maximum depth of 11/16th
inches down from floor surface and a minimum depth of 1 and
½ inches up into the rail
Measure distance, at each baluster, from the bottom of the
rail to the floor surface. Add 1 3/8th inches to
this measurement to determine baluster length
Cut balusters with metal cutting band saw or jigsaw
Balusters should slide up into the rail and down into the
floor. Be sure to test your baluster fit before applying adhesive.
Adjust hole size or baluster length if necessary
Slide baluster shoes onto top and bottom of balusters. The
baluster shoes are used to cover old holes and adhesive.
Install balusters using epoxy or polyurethane adhesive
