PORCH RAIL INSTALLATION INSTRUCTIONS • • • Level Rail . ........................................ 2 Stair Rail ........................................... 8 Care & Maintenance, Finishing.......
COMPONENT LIST LEVEL RAIL KIT Porch Rail was designed to meet the most stringent building codes. An evaluation report is available through your Porch Rail Distributor or through RDI Customer Service. COMPONENTS: Depending on the level kit and kit length you purchased your component list will vary. Use this as a guide to identify the individual components. A B I C D J K F E L H G Standard Rail Kit Wood Cover Rail Kit A.) Wood Top Cover X Sold Separately B.) Top Cover 1 X C.
STANDARD LEVEL RAIL KITS 1. 2. 3. Prepare all posts and mounting surfaces before installation. Establish the level placement of the lower rail so there is no more than a 4" space from the bottom of the rail to the standing surface. Mark the post or mounting surface at this dimension to determine the bottom rail height. (See Fig. 1) Measure the finished opening space between surfaces where the railing is to be installed.
. >> Continued from previous page. Tip : If using a power saw, a carbide tip blade of at least 60 teeth is recommended. Place one of the beam covers (E) across the opening where the railing is to be installed (Fig. 7). Measure from the mounting surface to the first baluster hole on each end (Fig. 8), and adjust until these dimensions are equal. Trace the post edge onto the beam cover (E) at each end (Fig. 9).
. 6. Insert mounting brackets (H) in each end of bottom beam (Fig. 12); ensure proper alignment (Fig. 13). Place the bottom beam on the marks determined in Step 2. Cut the bottom rail support (G) to the bottom space determined in Step 2 and place it under the bottom beam at the center point (Fig. 16 and 17). Secure the brackets to the post using mounting screws (J) (Fig. 14). Secure the brackets to the beam using mounting screws (K).
7. 8. 9. Snap the bottom beam cover (E) over the bottom beam (D) (Fig. 20, 21). Insert a baluster (F) in each hole of the bottom beam cover (E) (Fig. 22). If installing glass or iron balusters, insert foam strip (L) into baluster channel prior to snapping on beam cover (E). Starting at one end of the rail section, slide the top beam cover (E) (routed flat side facing down) on top of the balusters (Fig. 23).
10. 11. 12. Place the top beam (C), as oriented in Fig. 25, between the posts and on top of the balusters (Fig. 26). Measure for length (Fig. 29) and cut the top cover (B) to fit (Fig. 30). Slide the top beam cover (E) up onto the underside of the top beam (C) and snap into place (Fig. 32, 33). Secure the brackets to the post using mounting screws (J) (Fig. 27). Secure the brackets to the beam using mounting screws (K) (Fig. 28).
COMPONENT LIST STAIR RAIL Porch Rail was designed to meet the most stringent building codes. An evaluation report is available through your Porch Rail Distributor or through RDI Customer Service. COMPONENTS: Depending on the stair kit and kit length you purchased your component list will vary. Use this as a guide to identify the individual components. A B I C D J F E K H L G Standard Rail Kit Wood Cover Rail Kit A.) Wood Top Cover X Sold Separately B.) Top Cover 1 X C.) Top Beam 1 X D.
STANDARD STAIR KITS 1. 2. Prepare all posts and mounting surfaces before installation. Temporarily secure a plank on the nose of the stairs along side of the posts onto which you are installing the stair rail (Fig. 1). The thickness of the plank will determine the space between the stairs and the bottom rail. NOTE: Check with your local building code office for design load requirements for guard rails and bottom space requirements.
3. 4. Place a beam cover (E) on the temporary plank (Fig. 6). Insert mounting brackets (H) in each end of bottom beam (Fig. 11); ensure proper alignment. Set the bottom beam in position between the posts. (Fig. 12) NOTE: Routed holes in the bottom beam cover (E) are angled routs. Insure that the bottom beam with bottom cover is facing in the right direction to allow the balusters to stand plumb, i.e. straight up (Fig. 7). Secure the brackets to the post using mounting screws (J) (Fig. 13).
5. 6. 7. Place the bottom rail support (G) on the nose of the tread that is nearest the center of the section. Trace the bottom of the beam onto the bottom rail support and cut the support to match the angle. Place the cut support in position under the center of the bottom beam. Now drill through the beam perpendicular to the tread surface using a 3/16” bit.
8. 9. 10. Cut the top beam (C) and cover (E) on the angle indicated at the marks made in Step 7. (Fig. 20) Insert a baluster in each rout of the bottom beam cover (E) (Fig. 22). Insert the mounting brackets (H) into both ends of the top beam (C) (Fig. 24). The top bracket will be angled down and the bottom bracket will be angled up. Separate the pieces and cut the beam 1/2” shorter at the same angle. (Fig.
11. 12. 13. Cut the top cover (B) to length at the stair angle (Fig. 26, 27, 28). Snap the top cover (B) onto the top beam (C) by rolling the cover to one side, engaging the locking strip. Then, roll the top cover (B) to the other side while applying downward pressure. Work from one end of the rail to the other until the full length of the cover locks into place (Fig. 29).
WOOD COVER RAIL INSTALLATION 1 . 2 . 3 . If your top beam (D) was not previously cut (Step 3), measure your finished opening, deduct 1/2”, and cut. Place the top beam (D), as oriented in Fig. 2, between the posts and on top of the balusters (Fig. 3). Measure for length (Fig. 6) and cut the wood top cover (A) to fit. Insert mounting brackets (H) in each end of top beam (D) (Fig. 1); ensure proper alignment (Fig. 2). Secure the brackets to the post using mounting screws (J) (Fig. 4).
Note: A deck board or custom wood board may be attached to the top of the Porch Rail Wood Kits. To properly attach, 2 slots should be routed down the base of the board as shown below. Slots should be made equal distance from the boards center line. Follow steps for “Wood Cover Rail Installation” in this instruction guide to properly attach custom routed board. Center 1/4” 1/2” 1-1/8” 2-1/4” CARE AND MAINTENANCE All Porch Rail products other than textured top covers (B) are pre-finished products.
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