How to Install Iron Balusters

Step 1: Cover the work area

Lay drop cloths over the stairs, floors, furniture and anything else nearby. Cutting out wood balusters makes a lot of sawdust.

Step 2: Cut the old balusters in half

Cut each wood baluster through the middle with a reciprocating saw or jigsaw. Cutting them in half makes them much easier to pull out.

Step 3: Remove the old balusters

Work each half back and forth until the nails come loose, then pull it out. Use pliers to wiggle out any nails left behind.

Heads up: If your wood balusters were installed with dowel pins and glue, pulling them can break off part of the tread or handrail. Cut as close to the end as you can and grind the rest down smooth, or plan on replacing that tread or rail.

Step 4: Drill new holes (if you need them)

Skip this step if you’re reusing the holes from your old balusters. Otherwise, drill plumb (straight up and down) with a paddle bit sized for your balusters: 1″ to 1-1/2″ deep up into the handrail and 1/4″ to 1/2″ deep into the tread or floor. Adjust for the material you’re drilling into. For bit sizes and tips, see how to drill holes for iron balusters.

No shoes? On square balusters, you can use a mortising bit to cut a square hole so there’s no gap to hide.

Step 5: Cut the iron balusters to length

Measure from the bottom of the handrail to the top of the tread (or floor) at each baluster spot, and cut the baluster 3/4″ longer than that measurement. The extra length goes up into the handrail hole and down into the tread hole. Use a portaband or a chop saw with a metal-cutting blade.

Decide where you want the design on each baluster to line up before you cut. You can cut everything off one end, or take some off both ends to keep the pattern where you want it.

Step 6: Slide on the shoes (if you’re using them)

Shoes have to go on the baluster before it goes into the holes. Slide on one shoe for the bottom, and a second one if you want to cover the hole at the handrail too. Any shoe works as a top or bottom shoe. They’ll hang loose on the bar for now.

Step 7: Install the balusters

Put about a dime-size drop of epoxy in the top and bottom holes. Slide the baluster up into the handrail hole, swing the bottom over the tread hole, and drop it in. Check that each baluster is plumb and that your pattern lines up before the epoxy sets.

Step 8: Set the shoes

Once the epoxy in the holes has dried, slide the shoes into place against the tread and rail. Hold each one with a small dab of epoxy, or tighten the set screw if your shoes have one. Allow up to 24 hours for the epoxy to fully cure.

Tip: We recommend epoxy over set screws, especially on hammered balusters. A set screw pushes the bar to one side of the shoe so the gap looks uneven. With epoxy, you can center the shoe around the bar.

Stuck on something? Call a stair expert at (866) 727-9356 or send us your project for a free quote.