Aesthetically Pleasing Wrought Iron Baluster Preparation

Aligning the Do-Dads on the spindles takes a few steps to get the wrought iron that is irregularly shaped with no real measure point and uneven bar stock lengths to all line up correctly.

Here are the steps I use to get  the aesthetically pleasing look

of the Balusters on the Landings on the Custom Stair Project.

Time and Labor saving tips by Scotty used in 
Building these Custom Modern Stairs.  I snapped
 a few photos to help you build your own custom
 stairs and for an example of how the construction 
tip was used in the example. 

Contract Labor Project

Custom Modern Stairs is part of a Green Build Renovation Project located in Downtown StLouis Missouri

Step 1	Stock 35 inch Wrought Iron Baluster with twists fits perfectly in this handrail that is 37 inches off the floor.
Step   2		Using 37 1/2 inch Wrought Iron Baluster with Do-Dads   Align the Balusters Parallel to each other in groups of 4 or 5 (length of the speed square). Center the Do-Dads  in the flat portion of the middle of the Stock 35 inch Wrought Iron Baluster step 1
Step  3		I strongly suggest to make a prototype (and Don't Forget to Tag It (I used  Duck Tape).   Be sure to test fit this first baluster in various spots. All the Balusters with the Do-Dads will use this baluster as the guide.  Make sure this 1st baluster is 100% right.
Step  4		This is a critical step that must be done correctly.  Remember all those Do-Dads may not be all the same size.  And their irregular shape does not provide a spot for centering (easily) use the wire wrap as the guide to align the Do-Dads.(see close up picture in step 3) The wraps next to the Do-Dads are what the eye sees when out of alignment.
Step  5		With the Do-Dads all aligned. You can now mark the overall height or the bottom of the balusters with speed square.  From the Prototype in Step 3. See the thin red lines (guide cuts)  and also notice that all the  baluster bar lengths are different. TIP: If you tried to install these without making all the balusters the same length or not aligning the Do-Dads  with its neighbors difficult and increase the difficulty factor in the overall installation.
Step  6		We are now working on the opposite end of the balusters and marking the top of the balusters.   Be sure to make an extra mark so that you can tell the top from the bottom of the balusters. Balusters were delivered in groups of 10 wrapped in plastic.
Step  7		Now that the Balusters are marked to proper height and Do-Dads are centered in the Stock Bars you are now ready to cut them to proper length. I set the Balusters in a Jig Set Up to hold the balusters in place when cutting them with a Portable Metal Band Saw with metal blade (Milwaukee). (Remember we are doing hundreds and thousands of balusters in this project.   It is cost effective to use a bandsaw over the black abrasive cutoff blades that wear out fast)
		Prior to getting the wrought iron Balusters ready; I installed a Handrail using a Laser for the guide.

Thank You for stopping by-Share and Comment below. If additional information in needed or you have a question let me know. Together we can make a difference and create a future that will benefit everyone. Build a Green StLouis Green Building Tips and Resources via: Scotty- St Louis Renewable Energy Green Blog