How to Build a Stair Railing

This request took Ron to Barnardsville, North Carolina, a rural town on the western border of the state. Here, Toby and Susie Shelton live in a rustic home that was built by Susie's great, great grandparents. Toby and Susie's two-year old granddaughter, Hannah had recently discovered the thrill of stair climbing, but this particular staircase has no railing. Ron stopped by to help the Sheltons install a stair rail so that grandma and grandpa could breathe a little easier.

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1. Drawing:

• As with most home improvement projects, Ron began by creating a drawing of the staircase and the new railing. Because the house and existing staircase were very rustic, Ron's design was in keeping with this style. Ron's design used a 4x4 post with balusters that were simple and square without any fancy embellishments.

• To install the post, Ron held it in the proper position on the tread while Susie traced around the base with a carpenter's pencil.

• Before cutting the square out of the tread, they drilled four corner holes.
  

• Susie inserted the jigsaw blade into one of the four corner holes and began cutting. The holes allowed Susie to easily turn the corners as she was cutting.

• Once the hole was cut out, they slid the post through the opening to rest on the floor.

• They used a post level to check for plumb.

• To secure the post to the staircase, Toby drilled a couple of countersink holes into the post.

• Next, he drilled smaller shank or clearance holes inside those.

• He inserted carriage bolts through the holes.

• He secured the bolts with a washer and nut on the inside of the staircase with a ratchet.

• To cover up the carriage bolt heads, Ron suggested they use plugs created from pieces of oak dowel.

• Ron covered the plug with wood adhesive, placed it into the hole and tapped it securely into position with a hammer. They allowed the excess glue to dry until it became rubbery. Then it was easily lifted off with a chisel or knife.

3. Prepare hand rail:

• They clamped a 2 X 4 to the post to determine the proper angle for the railing.

• Ron attached a tape measure to a level and Toby held this level in a vertical position and read the measurement from the second stair to the bottom of the railing.