How to Make Metal Railings
Making metal railings will boost the aesthetic appeal to any business or home. Aged wood railings, for example, may splinter or damage over time. Many wooden railings are cut with specific designs or shapes that are often tough to find when one needs replacing. Removing old wood railings and replacing them with electrical metal conduit railings add a modern look to your staircase and provide rails that are rust and splinter-proof.
Things You'll Need
- Work gloves
- Safety glasses
- Dust mask
- Measuring tape
- Marker
- 3/4-inch metal conduit
- Hack saw
- Abrasive sanding pad
- Drill
- 3/4-inch-wide router bit
- 120-grit sand paper
- 1/2-inch-thick micro density fiberboard (MDF)
- Hand saw
- EMT hand bender
- 1/2-inch wood screws (multiple)
- Metal polish
- Clean rag
Instructions
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1
Slide on work gloves, safety glasses and a dust mask to protect your skin, eyes and lungs. Remove any existing rails from existing posts.
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2
Measure the length of an old rail. Subtract 1/4-inch from the length. Measure and cut a piece of 3/4-inch metal conduit to the subtract length. Repeat for as many additional metal rails as you need. The subtracted length will allow the metal rails to fit easily in between existing posts.
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3
Dull the ends of the metal rails with an abrasive sanding pad.
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4
Measure the length and width of an existing post. Cut a piece of 1/2-inch-thick MDF board to match these measurements. Repeat for each existing end post. Drill 3/4-inch holes into each MDF board so the MDF will fit flush against the posts with their holes directly in line with one another. The MDF will provide holes to catch each end of the metal rails.
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5
Bend the metal pipe, if necessary, to suit any twist and turns in the existing railing design. Slide the pipe into the EMT hand bender at the point where the pipe must make a 90- degree turn, for example. Adjust the pipe so the point where the pipe must bend is in line with the prefabricated star on the bender. Bend the pipe until the body of the pipe is in line with the prefabricated 90-degree marking on the bender. Repeat for any additional pipes that must be bent.
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6
Press one MDF piece flush against the post so the holes on both the MDF and the post are aligned. Drill three evenly spaced 1/2-inch screws through the MDF so it is secure to the post.
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7
Slide one metal rail into the top post hole surrounded by MDF. Repeat with additional pipe for any remaining post holes. Ask an assistant to help hold the pipes into the holes, if necessary. Slide a second piece of MDF over the free ends of the pipes.
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8
Adjust the free end of the pipe -- or pipes so they are in line with the holes on the opposite -- the second -- end post. Slide the second MDF piece down so it is flush against the second end post. Drill three evenly spaced 1/2-inch screws through the MDF so it is secure to the second end post. Repeat Steps 6 through 8 for additional railings and end posts.
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References
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