There is nothing quite like the look and feel of wrought iron stair rails to enhance the safety, beauty and ambiance of your home or workplace. And if you’re anything like me you can never have enough of that rustic appeal created by black iron railings on hand-pealed log newel posts.
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This is the 4th installment in our free video tutorial sponsored by KingMetals.com. This series is designed to teach you all the basic information needed to prepare, weld, paint and install beautiful iron railings for personal enjoyment or for friends and family.
If this is your first time here be sure you sign up for our Newsletter now so we are better able to keep you informed about our latest articles and future tutorials. Then click this link, Part 1 — How-to Install Log Newel Posts for Custom Iron Railings and get started from the beginning of this informative video series.
Are you ready to learn the most important step to successfully weld wrought iron stair rails?
So what’s your angle?
What’s the angle, or pitch of your stairs? Yes, that’s it.
The key to welding perfect stair railings time and time again is to properly establish the angle of your stairs before setting up and welding your new rails. And while there may be many techniques and formulas to figure the exact angle of every set of stairs, the easiest method is to simply purchase and use a basic angle finder.
Then, once you get back to your garage or shop, it is easy to set-up that exact same angle on your work table and metal-cutting bandsaw before you start cutting and welding your iron.
Click the video link below now and watch How-to Weld Wrought Iron Rails
Weld Like the Wind
So now that you have established the exact angle of your stairs, and you have taken time to cut all of your components and secure them all in place, it is all down hill. Now it is time to start welding and that’s the easy part.
Simply weld wrought iron stair rails like you would weld any other standard railing. Start at the beginning and keep on going to the end. Once you find your rhythm just work your way down the line until you run out of balusters to weld. Then flip it over and start burning more wire.
Hang ’em High
Next, it is time to weld on your mounting brackets. Some folks call these termination brackets because they represent where your railing ends or terminates. These mounting brackets are nothing more than plates, straps or pieces of angle iron that have been crafted to accept the mounting hardware.
In this example I am using 2 1/2″ x 1/4″ and 3 1/2″ x 1/4″ flat straps to fashion the mounting brackets.
For the lower mounting brackets I cut down and “bobbed” the corners off of the 2 1/2″ strap. The uppers were cut out of the 3 1/2″ strap on a 45 degree miter, long to short. Both of these top and bottom mounting brackets were then drilled using a 7/16″ metal twist drill bit to accept a 3/8″ lag bolt.
And the beat goes on…
Depending on the desired look and feel of your iron stair rails, you may choose to apply ‘texture’ to your termination brackets. This is easily achievable by simply beating the brackets on an anvil using a variety of mauls or hammers.
As you will see in the video above, the process to texture steel does not take much time or effort but will greatly add to the rustic appeal of your new wrought iron stair rails.
So that’s it. That is all you need to know when it comes time to weld iron stair rails. But if you feel like you might have missed something, or you still have questions, leave me a comment below or feel free to drop me an email.
Click this link now and move on to Part 5: How-t0 Mig-weld Iron Handrails