I really appreciate this site and everyones comments, critiques, and enthusiam. I hope someday we can meet in some way or another. I look forward to seeing everyones work , progress. Hearing your joys and pains of the creative process. It's good to share. Janet R.

Hi Curtis, The critical factor in railings(especially stair rails) is correct measurements of the space for the rails. After that, most of the variables can be controlled in your shop. First, measure the spaces for the rails, if it's new construction don't forget to take into account flooring, moulding, stair treads and bull nosing, etc. When your finished remeasure it again to make sure. Next, work up a good set of plans based on your measurements. Make sure you know your local codes, especially the 4"(varies slightly with different locations) rule for railings. From those plans, figure out your jigs and just how your going to build the rail, finish the rail, and install the rail.

As for finishes, if your going to weld on site I would try to stay away from powder coating. It is the cheapest, fastest, and possibly most durable finish, but colors are limited and it is very hard to match powder coats with paint. Little nicks and such are OK, but larger areas are going to stand out. If you can build the rail in one piece or sections that fasten together mechanically then powder coating is definitely an option. If the rail is going to be outside, you might consider having it galvanized first. Make that decision early though, b/c it will determine how the panels are built. If the rail is indoors, then you have a multitude of options for finishes.

Fastening the rail depends on the materials you're anchoring into and how rigid and strong your railing is. I usually use expansion anchors in cement, and lag screws into wood. If it's new construction, you can ask for blocking to be placed at all of your fastening points, if it's a remodel job, invest in a stud finder or have an experienced carpenter take a look at the space to find your anchoring points. The stronger and more rigid the railing, the more it will help support itself(usually at the expense of looks however).

These are just general tips that I use when constructing a rail. Once you measure the space and come up with a design, it will be much easier to answer your questions more specifically. I realize you were looking for answers to decide whether to take the job or not and am sorry I couldn't be more specific. If you feel uneasy about the installation side, you might consider working with an experienced contractor for the first one.

Jake

Jake thank you for taking the time to help out.

CW