Remove Old Balusters & Cut New Baluster

What happens in this clip

Begin by removing all existing old wooden balusters from your staircase. Once they are removed, measure the distance from the underside of the handrail to the surface of the stair tread where each new baluster will be installed. Add 3/8 of an inch to this measurement. Using a suitable cutting tool, cut the new wrought iron baluster to this precise length by removing material from its square bottom end.

Goal: Prepare the new baluster for installation to the correct length.

What's used

Tools

• Gloves
• Measuring Tape
• Safety Glasses
• Saw (Metal-cutting)
• Hacksaw

Materials

• New Wrought Iron Baluster Tap n' Twist
• Old Wooden Balusters

About the full video

This project guides you through replacing old wooden balusters with new wrought iron balusters using the 'Tap n' Twist' system. It involves removing old balusters, measuring and cutting new ones, installing specialized plugs and caps, assembling the new balusters with decorative shoes, and then securing them in place by twisting. The process is designed to be easy and reliable for transforming stairways, balconies, and walkways.

Step 4 of 6: Cut Wrought Iron Balusters

Using a metal-cutting saw (such as an angle grinder with a metal cut-off wheel or a reciprocating saw with a metal blade), carefully cut each wrought iron baluster to the exact length measured from the old baluster. Ensure cuts are straight and clean.

Open this step in the guide

Every video in Baluster Replacement

1. Step 1: Measure Existing Balusters

   • 0:49–2:09 Measure and Mark New Baluster (Using Existing Template)
   • 2:14–3:03 Size New Balusters
   • 0:24–0:40 Measure and Mark Baluster for Cutting

2. Step 2: Remove Existing Balusters

   • 0:16–0:29 Remove Old Wooden Balusters
   • 0:08–0:23 Remove Old Balusters and Clean Area
   • 1:31–3:50 Remove Old Balusters and Nails

3. Step 3: Prepare New Baluster Mounting Points

   • 0:17–1:26 Patch Old Baluster Holes

4. Step 4: Cut Wrought Iron Balusters

   • 0:07–0:08 Cut New Iron Balusters to Length
   • 4:17–5:02 Cut Your Balusters
   • 0:15–0:25 Remove Old Balusters & Cut New Baluster (this video)

5. Step 5: Install New Balusters

   • 3:41–5:00 Install Metal Balusters and Caulk
   • 0:06–0:08 Insert Balusters into Rails
   • 0:04–0:16 Install and Secure Iron Balusters

6. Step 6: Inspect and Finish

   • 6:38–7:50 Final Inspection and Cleanup
   • 0:16–0:27 Final Alignment and Quality Control
   • 0:18–0:26 Final Inspection and Cleanup