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using Rail Fastening Kit #________
OVERVIEW
Wood exterior Rails and Newel Posts are vulnerable to premature failure where Rails and Newels (or wall) meet. This is particularly true of Stair Rail installations and is caused when moisture remains in the small space between end of Rail and Newel.
Rather than caulking after installation, it is far better to caulk from "the inside out" during installation. This approach fills the entire space between Rail and Newel, is superior in several ways, and exposes less caulk to view!
It's also better to leave a small space between Rail and Newel and let the caulk serve as an "expansion joint". The following instructions create this space and incorporate "from the inside out" caulking. They also assume you are using a Subrail beneath your Handrail and our 2-part Sloped-top Bottom Rail. This system will minimize visible hardware while making installation and future maintenance much easier.
INSTRUCTIONS
As shown in Drawing #1, Brackets A and B will be installed between Newels and end of Rail. Brackets C and D will extend the thickness of the Bracket beyond the end of the Rails. Therefore, Rail lengths will be 3/16" less (the thickness of 2 Brackets) than the distance from Newel to Newel.
1. Measure the sloped distance from Newel to Newel at the points where Subrail is to be installed.
2. Trim Subrail to this length while also beveling the ends to the correct slope. Test fit this Subrail by temporarily inserting Brackets at each end of the Subrail, between Subrail and Newels. (For this test fitting, the Bracket in position C will be inverted so that it is between Subrail and lower Newel.)
3. Installing Bracket C onto Subrail
A. Use a second white Bracket to position the shorter leg of white Bracket C the thickness of itself beyond the lower end of the Subrail you prepared in Step 2. Mark the Subrail with a pencil through the two outer holes of the longer leg of one Bracket, as shown in Drawing #2.
B. Using a drill bit slightly smaller than the diameter of the screws, predrill perpendicular to the bottom of the Subrail at your 2 marks.
C. Screw Bracket C onto Subrail.
4. Installing Bracket A onto Subrail
When it's time to install the assembled Balustrade (Rails and Balusters - but Handrail will be installed last) into place, you will need to screw through the top of the Subrail, through white Bracket A, and into the upper Newel.
A. Hold Bracket A in postion and mark the two outer holes of the longer leg.
B. Using a drill bit slightly smaller than the diameter of the screws, predrill perpendicular to the bottom of the Subrail at your 2 marks.
C. Screw Bracket A onto Subrail.
D. Using the same drill bit, drill through the two holes in the shorter leg and entirely through the Subrail.
E. Hold Subrail in position. Using same drill bit, drill through Subrail and through shorter leg of Bracket A into the upper Newel. These two holes will become your pilot holes when it's time to install the Balustrade section.
5. Installing Bracket B onto Subrail
A. <<<<< 4.16.10 - rht will do a prototype >>>
6. Installing Bracket D onto Subrail
A. Using one of the galvanized t-shaped Brackets, hold it only the end of the bottom piece of the Sloped-top Bottom Rail so that the shorter portion of the "T" is entirely below the Rail, as shown in Phto # __.
B. Mark the positon of the two upper holes in the longer portion of the "T".
C. Using a drill bit slightly smaller than the diameter of the screws, predrill perpendicular to the bottom of the Subrail at your 2 marks.
C. Screw Bracket A onto Subrail.
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