Wikipedia defines welding as “a fabrication process that joins materials, usually metals.” This is done by melting the part of the materials to be joined and adding some additional molten joining material. When the molten material cools, it forms a strong bond or joint.

Welding is the most widely practiced way of joining metals together due to the efficiency and economy of the process. It has been estimated that approximately 50% of the Gross National Product of the USA arises from activities that are in some for or another related, perhaps remotely, to welding. As an example, farming may appear to have nothing to do with welding, but the equipment the framer uses to grow and harvest his crops will have used welding in their manufacturing process.

Until the advent of the 20th century, welding was confined to blacksmith shops where two pieces of metal were heated to very high temperatures in a forge and then hammered together until the joining occurred. This is what is called forge welding.

With the introduction of electricity into industrial processes, welding became both quicker and easy, and also more economical. Today there are 4 types of welding techniques that are commonly used.

· The most basic for is Arc Welding where the parts to be joined together are brought into contact with strong electrical current and heated. The molten parts are then joined together to form a weld. This is the low technology end of welding in its cheapest and least sophisticated form.

· Gas Welding is generally used for repair work especially in the case hollow items like tubes and pipes. Hot gas is forced onto the surfaces to be welded. This procedure requires the parts to be subjected to less heat and is suitable for material that may be damaged by exposure to high temperature. For this reason it is used in the jewellery industry which has to work with soft metal with low melting points.

· Resistance Welding requires that an additional sheet of material is used to cover the pieces that are to be welded together. This provides great strength to a weld, but the process requires expensive equipment and also the use of additional material to encase the weld which makes it expensive and not suitable for all applications.

· Laser Welding is the most modern technology available. High intensity lasers can be tightly focused and produce controllable heat on the surfaces to be welded very quickly. This is perfect for material which can be damaged by prolonged exposure to extreme heat. Laser welding is very accurate and can be used to produce even the smallest of welds. However, because of the high capital cost involved in purchasing this equipment, the cost of welding is also high.

Although the perception of welding is that of a simple process of heating and joining, it is a high technology industry with huge amounts being spent of research and development to find stronger, more accurate and cheaper methods. The welding process plays a big role in metallurgy with a constant effort underway to find newer and more weld friendly alloys.

Sheet metal is nothing but a metal rotated into a sheet having a thickness between the plate and the foil. It is one of the basic forms utilized in metal working and it can be bent and cut into different shapes. The thickness of this material varies from thin foil to thick plate. They are obtainable as coiled strip or as flat pieces. Coiled strips are nothing but the continuous running of the sheet. Different metals like brass, titanium, and aluminum, and copper, nickel, tin and steel are converted into sheets of metal. Sometimes, even precious metals like platinum, gold and silver are converted into sheet metals for decorative purposes. Every day different objects like car bodies, wings of airplane, building roofs, medical tables and tools are manufactured with the help of sheets of metal. The tools used for cutting the sheet metal differ according to the purpose for which the sheets of metal is going to be used.

Different tools like metal rollers, tip snips, etc. are being used to cut the sheet metal. The difficulty level in using sheet metal tools can be hard or easy; this depends on the tools being used. For instance, for the process of deep drawing, metal rollers can be used and thick sheets can be bent by using a tool called press-brake.

For the purpose of stamping designs and images in the sheet metal a tool called machine or stamping press is being used. Thus, each tool makes its own effect on the metal. The most important benefit of using these tools is that a tool available for one purpose need not be used for some other purpose. For instance for deep drawing of sheets of metal, the tool called rollers would be the best option, instead if the tool called press-brake is used for this purpose the desired result cannot be attained. So different tools can be used for different purpose, this helps the technician to shape the metal according to his desire.

Sheets of metal tools are used for different purposes like wheeling, deep drawing, ironing, cutting, bending, perforating, stamping, spinning, rolling, press-brake forming, roll forming, etc.

Sheet metal tools must be used with utmost care. It is better to use the sheet metal tools only after getting training in using them. If an inexperienced person uses the tools he may get some injuries and it is also safe to keep the sheet tools out of the reach of the children.

Tools Needed:

Drill
3/4″ speed bore drill bits - approximately 1 for every 20 balusters.
Caulking Gun
Angle Grinder or Metal Saw to cut iron balusters
1-5/8″ drywall screws
Jig Saw or circular saw.
Products needed:
Iron balusters of your choice and color
Baluster Shoes
Epoxy adhesive or polyurethane adhesive
Installation Instructions:

LAYOUT GUIDE AND DESIGN - Before ordering your balusters, make a detailed drawing of your stairway, layout in a straight line or circular line (depending on the stairway design) each of the steps and the number of balusters on each step, and the landing areas (flat areas) with the number of balusters in the landings. Assign a circle to each of the space. In other words, if your steps have 3 balusters per step, you would assign 3 circles to each step in your layout as shown below in diagram #2. Please make note that the layout has been determined and a number has been assigned to each baluster and then totaled to place the proper number for your order.

Step #1 Baluster Removal - Remove the wood baluster by cutting them with either a circular saw or a jig saw half way between the treads and the handrail. Pull out the lower portion and the upper portion and then remove any remaining nails left in the holes with pliers.

After the baluster has been removed, you will have either a hole in the tread like pictured above, or the area will be flat with no hole, depending on the installation of the old wood balusters.

Step #2 Drill Holes for Iron Balusters - You will now drill a 3/4″ hole in the center of this space vacated by the wood baluster, drill as deep as the drill will go, preferably 3-4″ deep.

Step #3 Measure the Baluster Length - Set the new iron balusters in this new 3/4″ hole UPSIDE DOWN and mark the other end (actually the bottom) of the balusters against the bottom of the handrail near the corresponding top hole. Be careful to align the top and bottom in a plumb (level) line as it is easy to move from one side to the other giving you an improper length. This mark is where you will cut the new iron baluster baluster. NOTE: By placing the baluster upside down in the hole and marking the other end, you are actually marking the bottom of the baluster. YOU ALWAYS CUT THE BOTTOM OF THE BALUSTER. When you are drilling holes, you will occassionally encounter nails in the lower framing. Do not worry if your drill penetrates the wood framing completely, sometimes this will happen.

Step #4 Baluster Cutting - Cut the baluster approximately 1/2″ shorter than the mark, this will allow for you to slide the baluster into the hole, and up inside the top hole of the handrail.

Always test your baluster fit before gluing. Slide your shoe onto the baluster. The baluster should slide down into the lower hole first, and then into the upper hole. If you drilled the hole deep enough and cut it properly, your baluster should fit in this space by filling the upper hole and still have 2″ into the lower hole.

Step # 5 - Adhesive in the TOP hole - Apply adhesive (epoxy or polyurethane) to the upper hole.

Step #6 Fastening the Baluster in the LOWER hole - Place a 1-5/8″ drywall screw into the lower hole on the side of the baluster at a 45 degree angle, wedging it into place. Repeat this process on the adjacent side if necessary. These two screws will wedge the baluster firmly into place holding it permanently.

Adhesive can also be applied.

Final Steps
Wipe off any adhesive left in the top hole.
Slide the shoe down over the baluster for a finished look.

Align the baluster so it is properly aligned.

Enjoy your new stairway.

Always wear safety glasses when operating power tools and use tools in the manner they were designed.

Neither Stairway Creations Supply or any of its employees assumes any liability for the installation of products purchased from our company. Installation instructions are general because each and every job will be different and certain conditions will have to be adapted to the individual situation. We assum no liability for use or misuse of any equipment or products.
Please make sure you comply with all building codes.

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