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How to drill holes for round balusters

Baluster guide for 3/4 round baluster installation

  1. Drill Guide for drilling (.900 - 23mm) holes for 7/8 Round Balusters by Dekor The drill jig is designed to fit over dimensional lumber (2x) on end. Simply drill your first hole put the male bushing into the hole that you just drilled and use the opposite end drill bushing to drill your next hole
  2. When drilling the holes in the bottom of the rail, the holes should be 1-1/2-inches deep. Cut the balusters 1/2-inch longer than the length of the baluster as above. Next, push the top of the baluster up into the hole in the bottom of the rail. Click to see full answer
  3. Simply put, measure and mark your drill points. Balusters are typically spaced 4 inches apart on center. We do have a spacing guide located here. Step 2 - Drill your Holes
  4. Using a nail set, mark the holes that correspond to the desired baluster and newel layout. Align the template with the bottom of the volute. Using a nail set, mark the holes that you used to mark the tread. Use these holes after the volute is installed to drill the appropriate diameter holes to accept thebalusters
  5. The baluster holes are laid out on the bottom side of the handrail, Bore Buster® is attached to the handrail, adjusted to the correct pitch and then each hole can then be then drilled, automatically centered and to the correct pitch. The unit is then moved to each subsequent layout mark in order to precisely drill that hole
  6. The balusters are 1/2″ square, i imagine around 9/16 or so diagonal. My question is what size hole to drill that will allow me to get the balusters in easily plus give enough room for the nozzle on the glue gun to shoot glue into the hole. Thank you, Charlie. X
  7. Round hole with Epoxy Only - This is easily the fastest method. You drill a round hole, install the iron baluster and leave it as is. There will be exposed gaps around the balusters, also meaning this is the most undesirable finished look. We do not recommend this method

Made a thing, we fabricator now This video shows you how to drill angled holes fast and accurately!To see a project where I used this technique, check out this video: https://youtu.be/scD_9..

How do you drill a hole in a baluster

You will only need to drill 1/2 or 9/16 holes, depending on which size baluster you are using. Square up the sides of the holes with a chisel after drilling. Cut The Metal Balusters: Measure the distance between the bottom of the handrail and the floor/tread surface. Cut the balusters 1-3/8 to 1-1/2 longer than the measured distance Drill an appropriate size hole for your balusters top and bottom. (If you don't want to use shoes to hide leftover gaps with square balusters, you can use a mortising bit and punch out a square hole instead.) Drill 1 inch to 1.5 inch deep up into the handrail. Drill 1/4 inch to 1/2 inch into the tread / floor Next, take the drill bit out of the correctly sized deep hole saw, and simply core (DRILL) round the stub of the baluster. Finally using vise grips, or a small pipe wrench, give it a twist, and out comes the remaing part of the baluster. The hole that is left is the perfect size for the new wood one

How to Drill Holes - Cheap Stair Part

Drill countersunk pilot holes at each end of the railing and into the post. You will have to plug these holes later. Add lag screws to hold the railing in place, but don't sink them all the way in yet. Layout and Cut Balusters NOTE: Make sure mounting screw holes are facing towards baluster pocket. Step 4 Drill Holes With bracket miter to stair or angle, follow drawing to the right. Drill a 7/32 hole and install the 3/16 stainless steel pin. Step 5 Mount Bracket With pin installed, slide bracket forward and lock in place. Set top rail onto balusters, center on mountin Interior balusters are the spindles that support the handrail. This type of system is built in four parts designed to fit together. The bottom rail has holes drilled at specific intervals that.

Using the Bore Buster to Drill Handrails - Baluster Boring

drilling holes for iron balusters - Fine Homebuildin

Installation of balusters on the dowels that represent round wooden spikes is performed as follows: drill the holes in the baluster ends and on the stringer/steps (they must be larger than for the metal studs); insert the dowel into the prepared grooves, using the glue similar to PVA for fastening Step 3. Begin attaching the baluster connectors in their positions. Place the included installation screws into each connector and then holding it firmly, position the point of the screw directly onto the center of the marked location. Using a drill, drive the screw into the railing until the connector pulls tight to it Step 1) Pin Top Baluster: Under the Handrail use the centering plug as a means to center the 2 ½ Attachment Screw in the old baluster hole (⅝ & ¾ diameter centering plugs are included in each kit but only one will be needed per baluster under the handrail). Adhesive can be used to secure the plugs but is not necessary The handrail has a plow or channel along the bottom. If you are not using shoes make sure your holes are drilled as tight as you can for round balusters. Round hole with Epoxy Only This is easily the fastest method. 2 drill the hole will be difficult because cut is under angle use of wisegrip is highly recommended

How to Install Square Iron Balusters With and Without Shoe

balusters per tread to find the center-to-center distance for the other balusters. For example, if the run is 10 and the maximum spacing required by code is 4; 10 divided by 4 equals 2-1/2 spaces required per tread. Round this up to 3 spaces. Thus, 3 balusters per tread are required. 10 run divided by 3 balusters The Dekor Baluster Drill Jig makes it simple to install Dekor Baluster End Caps. Once you drill the first hole, insert the connector & place the jig over it. Drill the hole for the next connector, place it, & keep moving down the rail. Your Dekor Balusters will be perfectly spaced 4-5/8″ on center Step 4 - Drill the Holes Obtain a special baluster drill bit that will create a hole and a secondary thread for the bolts you use to secure the balusters to the staircase. Ask your home improvement center representative for advice on what drill bit to select. If there are no holes in your stair treads to fit your balusters, than create them

Custom baluster drilling fixture

The drill guide features a positive-stop depth control, spring return to keep the guide ready and protractor for easy angle settings in 5 degree increments. The guide even includes a V-base for drilling round stock. Guide your 3/8 in. or 1/2 in. drill at any angle from 45 to 90 degrees with total accuracy. Positive-stop depth control balusters against the rail to make sure your pattern and spacing are correct. Once proper spacing (refer to your local build-ing code) has been established, mark your rail and cap with a pencil where you will drill your holes according to the diameter of your baluster. Drill 1/2 inch deep into the cap and 1 inch deep into your handrail Install Balusters. Drill 1-inch-deep pilot holes with a 9/32-inch drill bit on the center of the crosses you drew on the stair treads and the underside of the stair rail. Find the center line of. Installing Wooden Tapered Balusters. Mike5000 | Posted in Construction Techniques on February 6, 2012 10:49am. My new stairs are finished and the only thing left is to install the turned, wooden balusters. The bottoms have 3/4″ diameter tenons and they are round and tapered at the top. The tenons are 3/4 to 1″ long If using round metal balusters, insert rail inserts for round balusters into the top and bottom rail routed holes. Place round metal baluster through the inserts. (Round balusters must be a minimum of 32-in. long). Pre-drill holes: 1/8-in. bit. Attach top bracket flange. Place top rail brackets over each end of top rail

Super Easy Way to Drill Angled Holes! - YouTub

  1. 2. Add a pilot hole to the angled jig by drilling into the angled edge. Drill into the angled part of the wood so that the drill is perpendicular to the wood. This will create the perfect angle for drilling into other pieces of wood. Drill all the way through the wood to make the pilot hole
  2. The hole must also be deep enough to allow the baluster to slide up into it high enough to clear the tread cap or landing shoe before it is straightened out and dropped into the 5/8 hole. Typically if your baluster extends into the upper hole 1 and the lower hole ½ the depth of the upper hole is 1 ¾ - 2 deep
  3. Holes TRIM BALUSTERS ASSEMBLE BALUSTER SECTION 6 • Place the Bottom Rail and the Top Support Rail together as shown to keep the holes aligned. • Separate the two rails, once all holes are drilled. Drill 3/16 hole through the top Support Rail using the Bottom Rail holes for alignment, drilling at the same angle used to cut rail ends.
  4. Drill 1 holes in the rails following your baluster centerline marks. Use cedar shims on the bottom of the newel posts to plumb the newel posts if necessary. Clamp a temporary support prop to each post to steady the post

To drill the wood baluster purchase a long drill bit, and depending on the height of your baluster you can either drill the center hole all the way from the top down, or you'll have to drill as far as you can and then flip the baluster and drill from the bottom having the holes meet in the middle to get your center hole hole at each end. If using round metal balusters, insert rail Inserts for round balusters into the top and bottom rail routed holes. Place round metal baluster through the inserts. (Round balusters must be a minimum of 32-in. long). Remove bottom rail and mark bottom bracket flange holes. Pre-drill holes: 1/8-in. bit. Attach bottom bracket flange The use of wood or cabinet screws helps to lock the baluster in, serving as both a wedge and forcing the baluster on center. Round 5/8″ iron or metal balusters can be installed without shoes simply by drilling a 5/8″ hole into the handrail and into the floor and following the same procedure outlined above Hidden Connectors for Classic Round 3/4 Balusters by Deckorators. When installing balusters into both upper and lower rails, make sure the holes you drill won't cause you to lose any rail height. In fact, you can avoid the risk by not drilling baluster holes at all A special stair drill bit is needed for this step. Use the stair bit and drill a pilot hole for the baluster bolt directly into the tread. Make sure that it is straight. Step 5 - Install Wood Balusters. After the pilot holes are drilled into the bottom of the baluster and into the stair tread, you can begin to install the baluster itself. Screw.

Baluster Installation How to - Baluster Guide - DecksDirec

  1. e the length of the top (A) (E) and bottom (B) rail sections. The 10 balusters contained in this package should fit a 4'(121.9 cm) section of rail. S TEP 2: C ut top 2x4 (A),2x4 (E) and bottom 2x4 (B) rails to length and mark and drill holes (C) along the length of the rails, evenly spaced, to a depth of 3/4(1.9) using a 13/16.
  2. Deckorators Classic baluster connectors are simple and easy to install. Baluster connectors install on the top and bottom of the deck rails to create the perfect connection between the top and bottom rail without the need to drill large holes. Secures Classic Balusters to the rail without routing holes. Includes Stainless Steel Screws
  3. the center line if using glass). Using the baluster as a guide, drill 9/64 holes in the rails at each baluster location. Use a 2x4 as a spacer block to space the next baluster. Working toward the ends, drill and attach each baluster with the screws provided (Figure 5). Step 13 (optional) Cut the cap rail and cap rail insert to length. (Note.

Assembling The Wheelbarrow. To assemble the wheelbarrow flip your crate over then center one of the balusters with the drilled hole at the front in the center the second outer slat of the crate making sure you have a 6 overhang at the front of the crate then center the back end of the baluster at an angle between the two outer slats. Attach the front of the baluster to the crate using a 2. Baluster Designs Wood. Wooden Stair Balusters. Insert the baluster into the newly drilled hole in the bottom of the railing. Apply a small amount of glue or epoxy to ensure a safer fit. Allow the glue or epoxy to dry completely before continuing. Apply wood or epoxy glue to the bottom of the baluster that meets the footprint of the ladder

Cut through the center of each baluster, then remove each section of the baluster by pulling from the top and bottom holes. Use blue electrical tape (Image 1) to mark your spade bit at the correct depth needed for drilling. Use the spade bit to drill holes in the handrail (Image 2) and the bottom seal plate to set new balusters 2) drill the hole (will be difficult because cut is under angle, use of wisegrip is highly recommended); 3) cut the thread in this hole and fasten now balusters to metal bracket; SECOND method: Widen up existing hole in metal bracket so the baluster can go through it and then just do everything as it was posted on this page. Hope this helps, Mik Consequently, cut the handrails at 45º, as in the image. Next, drill several pilot holes with the machine drill. Fix the handrail, by aligning carefully the its edges along the top of the posts. Last but not least, apply adhesive to the mitered ends and secure the joint with screws. Wooden railings and balusters

baluster placement. At each baluster location drill the appropriate diameter hole 3/8 deep into the treads and a 1/2 diameter hole approximately 1 deep in the underside of the rail. NOTE: The tops of Medallion and Belly Baluster are square and will require a 11/16 diameter hole in the rail. 2. With all baluster holes drilled an Using the marks made proceed to drill the holes using a bit that fits the pins on the baluster. *A good secure way to fasten baluster is with double lag screws available from Moldings One. Proceed to cut the balusters to the correct length. Insert the baluster into the handrail and make sure to use level. Now cut the handrail fillet and match. 5. Cut baluster spacers the same length as rails. Make sure the baluster spacer holes are equally spaced to ensure balusters will line up. NOTES: » If using optional rail gaskets, subtract 1/16 (1.6 mm) from each end. » Attach baluster spacers to railing before cutting to allow for cleaner cut and less work

BQKKWIN Square Hole Drill Bit, 4Pcs Woodworking Mortiser Square Drill Bits, Spiral Drill bits Kits Mortise Press, Wood Drill Set Space Hole Drill (6.4 mm / 8 mm / 9.5 mm / 12 mm) 3.3 out of 5 stars. 3. $27.99 The Deckorators Scenic baluster has four pre-drilled holes. The pre-drilled holes are 1-1/2 inch from the bottom of the baluster to the center of the pre-drilled hole. It is 1-1/4 inch distance from the side of the baluster to the center of the hole. What balusters should I choose for a wrought iron look

Stair Railing | Ana White Woodworking Projects

Dec 9, 2014 - Shoes for iron balusters are also called boots, collars or caps. The purpose of a shoe is to give a more finished look and to hide gaps left over from drilling holes. Baluster shoes are purely decorative and do not support the baluster structurally at all. Most of the shoes are available in the same finishes as the balusters. See more ideas about iron balusters, drilling holes. 2. Prepare location where new hollow metal baluster will 2 be installed. If no hole exists in the tread where wood baluster was removed, mark on tread at a point that is directly below the center-point of the hole directly above it in the rail. Using a drill and 3/4 diameter drill bit, drill a hole that is 7/8 to 1 deep. 1 2 STE

A Simple Iron Baluster Installation Guide for Staircase

at marked location drill a hole using a 3/16 drill bit in the center of the channel. Foot block is to be installed at last step. For spans over 6' in commercial applications, mark and drill two locations spaced evenly apart for two foot blocks. Cutting Bottom Stair Rail and Baluster Spacer 7. Keeping baluster spacer in rail, cut along marks. The use of wood or cabinet screws helps to lock the baluster in, serving as both a wedge and forcing the baluster on center. Round 5/8 iron or metal balusters can be installed without shoes simply by drilling a 5/8 hole into the handrail and into the floor and following the same procedure outlined above Just drill a round hole and install the square baluster, could it be any easier than that? With the help of our patented End Caps, it is that easy. You can find the End Caps on the DeKor Accessories page. Our 3/4 square balusters are available in Plain, 1 or 2 Baskets and 1 or 2 Casey collars in 27 and 32 lengths

Fiberon Homeselect 1-Pair White Traditional Stair Bracket

baluster to floor, drill a ¾ by 1 deep hole for each baluster centre. Step 4 Cut the top of each baluster to proper height. Note: Do not forget to add the depth of the groove on the handrail. Step 5 Insert each baluster into the dowel hole or shoerail and the top into the plow of the handrail. Use a level to ensure they are plum Step 4. Drill the wire hole. Using a ½ in drill bit, drill a hole from the side of the handrail into the core of the deck post. Be sure to avoid mounting the rail light in line with the groove that you have made previously This two piece split shoe for square balusters, pickets and posts wraps around the base of a square bar and is a great way to finish off or retrofit a railing or fence project. Cover up drill holes, mismatched concrete or caulking, all without uninstalling or disassembling the project. All you need is a screwdriver! Retrofit an existing railing or fence without taking it apart, indoors or. Drill holes for baluster pipe locations in bottom rail sections. Use carbide hole saw/drill bit combination with center pilot drill bit. Use at least 1 hole saw size and 1/4″ pilot drill size to allow for baluster pipe plumb variance. Tip: Swimming the drill in a circle while drilling will simplify removing the marble rail plug

Stair Warehouse Presents How To Install Metal Balusters

  1. um Baluster Square DRILL BALUSTER 4 HOLES 5 Tip for Bottom Rail: Partially drive screws into all Balusters before driving them in completely. Brackets must be on the side of the rail facing the stairs. Bottom Rai
  2. application for the pre-drilled holes in the handrail, taking care not to put too much in each hole. (Fig.22 & Fig.23). Note: wipe off any excess adhesive from the rails and balusters immediately. Place the baluster at an angle and slide it into the pre-drilled hole in the handrail as far up as it will go so it makes contact with the adhesive
  3. I drill a 9/16 hole in the tread to a depth of 3/4, and then use one of the cut off pieces to drive into the hole to square it up. A 1/2 hole is drilled into the bottom side of the handrail. These sizes will hold the baluster firmly in place with no need for epoxy as I have seen suggested in some installation instructions
  4. imum depth of 1 and ½ inches up into the rail: The baluster should be cut from the bottom. The top of most balusters have a turned.
  5. Installing metal ballusters. 11-19-2003, 08:57 PM. I did a search and came across a recent thread on installing metal ballusters. The details included drilling a round hole then using an impact chisel with a 1/2 square mortising bit to square it up. I just received my balusters and the thickness of the balusters is ~9/16-5/8 so a 1/2 bit.
  6. um Balusters (Bottom Rail for Square Composite Balusters Shown) Gaskets are optional and can be used to provide a clean edge on cut rails. For 90 degree installations only. Not for angle or stair installations. When pre-drilling 9/64 hole to prep for attaching brackets onto Top and Bottom Rails, it is important to.

How To Install Iron Balusters - Cheap Stair Part

Place the end caps on the balusters. Thread wire through the hole down to the channel. Pull the wire through from the channel side until the cap is in place. Insert the caps for the unlighted balusters into the top rail. Insert the unlighted balusters into the caps. Assemble the top and bottom rail and use ratchet straps to tie rail together NEW! No Cutting, No Drilling. Slide Iron Baluster Single Twist. Adjustable from 30 to 38 (use extension to increase length to 42 - sold separately). Do it yourself installation has never been easier. Using only a drill, screwdriver and an allen wrench you can replace your old wood spindles without the expense of a professional installer The drill jig is designed to fit over dimensional lumber (2x) on end. Simply drill your first hole put the male bushing into the hole that you just drilled and use the opposite end drill bushing to drill your next hole. Using the jig will give you 4-5/8 on center for baluster installation and meets code for spacing Mark the spot with pencil or tape before you begin. As the old saying goes, Measure twice, cut once.. That truism can apply, too, to drilling pilot holes: Before touching drill bit to wood.

RE-drilling stair tread for bigger balusters Woodworking

Round top balusters are simply drilled into the bottom of the rail. There are several methods to attach the newel to the floor. I prefer to use a pair of rail bolts as shown below. I drill a 1 inch hole in the side of the posts about 1 3/4 up from the bottom. 1 inch plugs fill the hole. You then drill a 3/8s hole from the bottom of the post to. Use a drill/driver with a combination countersink bit to bore ⅛-inch pilot holes through the template and into the baluster blank and the cleats on all sides BQKKWIN Square Hole Drill Bit, 4Pcs Woodworking Mortiser Square Drill Bits, Spiral Drill bits Kits Mortise Press, Wood Drill Set Space Hole Drill (6.4 mm / 8 mm / 9.5 mm / 12 mm) 3.3 out.

How do you drill holes in metal balusters

brackets with side holes) b. Begin at one side of rail and align fi rst baluster with fi rst routed hole on bottom side of top rail and snap top rail into position c. Continue down the line of balusters installing balusters into top rail d. Install brackets i. Using 5/32 drill bit, pre-drill fi rst top bracket screw hole (see hole drill gauge 6039-GAU2 page 134). Wall screws not included. Setback is 2.95 6039 Round Rail Combine the warmth of wood with stainless steel to form a unique wall rail system or over the post stairway utilizing our stainless steel newels with stainless steel or wood balusters. Stainless Steel fittings are to be used with ou adjustments. The installation of the balusters is complete. (See Drawing 5) Drawing 4: BALUSTER SPACER BLOCK Drawings 4B & 4C: PRE-DRILL 1/ 8 DIAMETER HOLES THROUGH PVC RAIL & INTO BALUSTER INSERT & SCREW RAIL TO BALUSTER INSERTS 1. INSTALL INSERTS THAT WILL RECEIVE SCREWS INTO ENDS OF HOLLOW, TURNED BALUSTERS A

Video: How to Install Balusters and Handrail System - Spectis

Deck Railing Plans | MyOutdoorPlans | Free Woodworking

I need to accurately drill multiple holes in steel pipe (1.25-2 diameter, 65-100 mil wall thickness, about 10ft long). I need to drill a half-dozen or so evenly-spaced aligned pairs of holes all the way through the pipe. So the two holes in each pair need to be diametrically opposite • Baluster Hole Depth º Treads, Knee Wall or Floor holes - drilled ½ deep º Handrail holes - drilled 1½ deep • We recommend laying out your balusters in the pattern you plan to use before starting the installation • Mark where you will want to install each baluster. This is where you will drill your mounting holes 11 12 9 1 Rotate the rod 90 degrees and repeat. This will give you an X in the center. Use a nail or screw like a center punch to make a dimple to prevent the drill bit from wandering as you start the hole. #12 DonShock, Oct 21, 2009. davidt1 Loaded Pockets Please note that the JLC forums are now displayed read-only. New posts are no longer possible, but the collected work of building professionals sharing information remains available here as a resource to the JLC community

Stairs Railing: Building a Staircase Railing with

b. Insert all balusters through the square holes in rails, making sure the hole in each baluster goes in the same direction facing the side with the two (2) small ridges (Fig. 5). c. Make sure the balusters in the rails are about 2 above the rail and in-line with each other (Fig. 5). d. Snap in bumps from locking strip into holes of th position intermediate baluster bracket directly on surface centered between posts. • At this time, do not attach intermediate baluster brackets. STEP 1 - PRE-DRILL RAILS FOR INTERMEDIATE BALUSTER BRACKETS STEP 6 - INSTALL HORIZONTAL BALUSTERS • Insert horizontal balusters through holes of intermediate baluster Using a drill and a Tenon cutter, shape each end of the balusters from 2 inches to 1 1/2 inches. Using a caulking gun with a tube of glue, place a dab of construction adhesive in each hole in the rail and insert the balusters into the top and bottom rail. An extra set of hands is necessary to keep the assembly together

Drill a hole onto the joist where the newel post is bolted. Then take a piece of wood and apply wood glue on it. Take the glued piece of wood and push it into the drilled hole until the wood is on the same level with the surface of the post. Do not leave the place looking dab but paint it to have a uniform look When autocomplete results are available use up and down arrows to review and enter to select. Touch device users, explore by touch or with swipe gestures How do you attach balusters? Install Balusters Drill 1-inch-deep pilot holes with a 9/32-inch drill bit on the center of the crosses you drew on the stair treads and the underside of the stair rail. Find the center line of the bottom and tops of the balusters and drill pilot holes. Place a dowel screwdriver attachment onto your drill

How do you drill holes for stair balusters? With this type of installation, the bottom square on each of the balusters is the same length. Square Hole using a Hollow Mortise - This is a time consuming method where you drill a round hole, take a square hollow mortise, and hammer out the square. Drill 1 inch to 1.5 inch deep up into the handrail Drill 1-inch-deep pilot holes with a 9/32-inch drill bit on the center of the crosses you drew on the stair treads and the underside of the stair rail. Find the center line of the bottom and tops of the balusters and drill pilot holes. Place a dowel screwdriver attachment onto your drill No one likes to drill holes and put screws in their wooden banister. With spindles, velcro adapters, and clamps, this can be avoided. They can be used with round or square posts in any combination to ensure the proper and secure mounting of your gate. After installing the gate, try the firmness of the gate The balusters were doweled into the plywood subtreads under the carpeting and just toenailed into the railing. I was planning on using a forstner bit to drill the holes into the new treads. I was also going to use the forstner to drill the bottoms of the balusters if that is my best option for doweling them Drill a guide hole at the desired angle. You can cut a 2x4 at the exact angle using a radial saw and use it as a jig for the drill (see photos below). Use a hole saw with a pilot bit (or a forstner bit) to cut the larger hole using the initial guide hole for precision. Share. Improve this answer

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Prepare the Holes for the Baluster Pins Drill Holes in the toe rail to receive the pins on the bottom of the balusters. Use a spade or paddle bit that corresponds to the size of the pin on the bottom of your baluster. Go back and remove the tape after the holes have been drilled 3/4 round. Lengths Available: 26 for a 36 rail 32 for a 42 rail 36 for a 48 rail. Balusters Per Foot: 2-1/2. Baluster Connectors. Straight Connectors - Install on the top and bottom of the deck rails to create a perfect connection between the rails. Angle Connectors - Designed to work with the deck rails for stairs between 30 - 35 degrees

Base Shoes for Iron Balusters for Staircase InstallationModern Stair Railing only $12

A square file is a very useful shaping tool that can be used for a variety of purposes Fitting the balusters is not difficult, especially if you have follow the instructions as describe din the project. Use 2×2 lumber to build the components. Align the balusters into place and drill pilot holes before inserting the galvanized screws. Place a small block of wood (2-3″ wide) between the balusters, if you want to get consistent gaps Mark the location of the bracket holes. Remove the top rail and balusters. Pre-drill the holes with a 5/32 in. bit, angling slightly upward and inward to allow for clearance from the rail once repositioned for securing Then rip both of these 2×4 boards to 2 1/2″ wide and drill pocket holes on both ends of the handrail. Step 5 - Cut Balusters for the Horizontal Section When cutting balusters, it's important to make them all exactly the same length