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Looking to replace wood balusters with iron on a balcony for a customer. Customer wants to keep existing newels and top rail. Couple of issues come to mind; hiding the holes in the bottom of the top rail, spacing between the new balusters vs. the old (code?), length (cut the 44" ones or special order the actual length needed). Any hints ,tips, smart advice would be greatly appreciated. Also any thoughts on pricing a project like this would be helpful.

Hope everyone is off to a prosperous New Year.
 

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PLEASE COMPLETE YOUR PROFILE, AND CONTINUE TO THE INTRO PAGE AND TELL US A LITTLE ABOUT YOURSELF AND YOUR PROFESSIONAL EXPERIENCE, THANKYOU AND WELCOME TO CT" GMOD


Build up the bottom rail, build down the underside of the top rail, lay out according to code, base buildup dimensions on available spindle lengths.
 

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Working with iron balusters

The holes you cover with shoes .To cut balusters you need chopbox or bendsaw.Glue balusters with epoxy.
If you ware in Illinois I could help you with the project;)
Remis
 

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The new balusters will be about the same size as wood 1/2 vs 5/8,
If it is an old handrail 6", centers just put another in between.
I use PL to glue, dries to wood color a lot easier than epoxy.
 
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