How to Weld Handrails for a Deck

Welding handrails for a deck allows for absolute customization and personal touches that you don't get from pre-fabricated handrails. The skill of welding is a learned art and required practice, but once mastered can offer strength to a project and the added benefits of rust protection. Use these steps to create and weld custom handrails for your deck.

Instructions

Difficulty: Challenging

Things You’ll Need:

• 1 1/2" to 2" round or square tubing
• Tape measure
• Chop saw
• Hard wire welding machine
• Work table
• Square
• Grinder
• Hole saw bit (optional)
• Soap stone or marker
• Screw clamps
• Metal cleaning product
• Paint or clear coat

1. Take all measurements for where the handrail will go on the deck. Write down measurements carefully and draw a sketch of what it should look like. Create a cut list off of the sketch.
2. Mark tubing with soap stone or a marker according to the cut list. Cut all pieces needed using a chop saw and the square to measure and ensure even cuts.
3. Lay out all the pieces together on your work table. This ensures the cuts are correct. If satisfied, clamp all pieces down to the work table the way you want it to go together.
4. Tack-weld each piece together, making sure it stays square as you work. Test-fit the handrail to the deck in the desired position to ensure a proper fit.
5. Place the piece back on the work table. Weld out a piece from one end to the other. Flip the piece over and repeat.
6. Prepare the piece for painting by first grinding all the welds with a grinder. This will remove burrs and make all weld locations smooth. Once smooth, wipe the piece down thoroughly with metal cleaning chemicals.
7. Paint the piece with a rust-proof paint to protect it. Use a clear coat or a color based on the look you want to achieve.

Tips & Warnings

• Use rust-proof paint to lengthen the life of the handrail.
• Check local building codes for height requirements on handrails.
• Wear all safety equipment while welding to avoid injury.
• Always use the old adage "Measure twice, cut once".

Who Can Help:

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