We start in our shop, where each baluster, or picket, is cut to length. The joint between baluster and bottom rail is a typical point of failure in exterior wooden handrails, so we take extra care with the chemical treatment and fastening method of this joint.
Each baluster is soaked in a wood preservative before the end grain is primed.
The bottom rail is milled in two parts. The balusters are fastened through the top member of the bottom rail. The fasteners are then hidden from view, which is aesthetically pleasing, and they don't penetrate the surface of the wood, which is an opportunity for water to turn to rot.
The joint between the top and bottom member is then glued, secured with biscuits and clamped overnight.
Above is the lower member of the bottom rail; the upper already has the balusters attached.
John cleans up the excess glue. We will install this section but leave the clamps overnight to allow the glue to dry.
The handrail has only a few screw holes where it meets the posts; these are filled with Abatron's Wood Epox to ensure the putty moves with the wood and won't be a point of failure.
The staircase is suspended off the patio, hanging on joist hangers.
The staircase is long enough to require a mid-span support. It is also made entirely of treated lumber to prevent rot. We treated each cut we made into the lumber with a copper based wood preservative. The bases of the supports have a PVC boot between the wood and the brick patio.
