Deckorators CXT6 Rail - Manual (Page 3)

PAGE 3 - 6' CXT Rail_ENG
Step 1: Cedar or pressure-treated pine 4x4 railing posts provide the
structural strength for the railing. The length of each post is determined
by the total of the stair stringer width (7-1/4") + tread thickness (1") +
railing height (36" or 42") + spacing for post cap (1-1/4") = 45-1/2" or
51-1/2".
Step 2: Position, plumb with a level, and clamp the rail post on the
interior face of the stair stringer. Plumb again. The 4x4 railing post
should be bolted to the inside of the stair stringer using two 1/2" x 6"
galvanized carriage bolts. Corner posts use a third carriage bolt inserted
through the adjacent joist. Ground-level posts should be set in concrete.
Step 3: Complete stair tread installation prior to installing post sleeves. Trim
4x4 post sleeves to length. Post sleeves should be a minimum of 1-1/2"
longer than the railing height to accommodate a post cap. Slide a trimmed
post sleeve over each 4x4 railing post. Use shims as needed to create a
snug fit. Slide a post base trim over each post sleeve.
Step 4: Note! The rails are pre-drilled. To ensure the outer balusters are equally
spaced, the rail components require trimming at both ends. Using the lower pre-
drilled rail as a guide, place it adjacent the post sleeves and center the rail
so the furthest pre-drilled holes for the balusters are equal distances from
the post sleeves. Using the posts as a guide, mark the angle for the beveled
cut vertically through the rail section. Mark the gap between the posts onto
the rail and trim to fit.
Step 5: Note! To ensure the balusters are installed plumb, the holes between
the rail sections must all be aligned. Tip: Use a gauge pin or a 3/32" drill bit
to ensure the holes are aligned. Using the trimmed lower rail as a guide,
set the upper inner rail for the system on top of the trimmed bottom rail
and align the pre-drilled holes. Mark the cut lines on the inner rail with
a pencil.
Note! To allow for the thickness of the brackets, the inner rails
should be 1/8" shorter than the lower rails with all holes equally spaced.
Remove an additional 1/16" from the pencil mark on each end and trim
the inner rail to length. Repeat for the second inner rail (fig. 7).
Stair Railing Installation Instructions
6' Rail Installation Instructions continued
fig. 7
Step 13: Measure the distance between the posts and trim the upper top rail
to length and set on the assembly.
Taking care not to drill all the way through
the upper rail, use a 1/8" drill bit to pre-drill four 1-1/2" deep holes, equally
spaced, through the underside of the inner rail and into the underside of the
upper rail. Tip: Place a piece of tape 1-1/2" from the end of the drill bit. Do not
drill past the tape. Fasten cap rail in place using four 1-1/2" pan head screws.
Step 14: Apply construction adhesive to the inside edges of the post caps and
place over each post sleeve.
fig. 6
Step 11: Determine the length of the balusters (fig. 3). Fig. 3 illustrates
how a 36" high railing might be sized. Starting with a 3" sweep + 2" for the
bottom railing, 29" baluster height + 2" for the top rail = a 36" rail height.
If these are the dimensions that you are going to use, cut the balusters to
29" length using a cut-off or miter saw. Use 35" balusters for 42" railings. If
you want to have your railing at a different height, use fig. 3 as a planning
tool to determine the height to cut the post sleeves and the balusters.
If you
are using 32" glass balusters, your overall railing height will be 39". Note:
Use a fixture to ensure a consistent length (+/- 1/16"). Trim the balusters to the
required length. Install balusters on each baluster connector. Gently tap the
balusters with a rubber mallet to eliminate any gaps. Check for level end
to end.
Tip: Wrap painters tape around the back side of both posts and place
balusters against the tape. The tape will balance the balusters in place until
the upper rails are installed. Remove tape when upper rail is in place.
Step 12: Important: When using
Deckorators Designer Baluster
Connectors (both Estate and
Classic), the upper inner rail must
be inverted (fig. 5). Use an exterior
adhesive on the underside of the
Designer Baluster Connectors
to prevent the balusters from
spinning. Install the baluster
connectors on the underside of the top inner rail (fig. 6). Set the rail on to
the balusters, gently tapping the rail to remove any gaps. Attach the inner
rail to the brackets by pre-drilling eight 1/8" holes at each bracket hole
and into the inner rail. Fasten the rail to the bracket using eight 1" long
countersunk screws.
Designer
Baluster
Connector
Inverted
Inner
Rail
fig. 5