Cut New Iron Balusters to Length

What happens in this clip

The new iron balusters typically come in standard lengths and will need to be cut to fit the specific height and angle of your staircase. In a workshop setting, secure each new iron baluster in a bench vise. Use a metal-cutting tool, such as a hacksaw, angle grinder, or a chop saw with a metal-cutting blade, to cut the balusters to the precise required length. Ensure the cuts are straight and clean. If your balusters have decorative elements, plan your cuts carefully to maintain symmetry.

Goal: Adjust the length of new iron balusters to fit the staircase

What's used

Tools

• Bench Vise
• Measuring Tape
• Metal-Cutting Tool
• Angle grinder
• Chop saw with metal blade
• New Iron Balusters
• Safety Glasses
• Work Gloves

About the full video

This project details the process of upgrading an existing staircase by replacing old wooden balusters with new, modern iron balusters. The transformation involves removing the old balusters, preparing the existing handrail and base rail, installing new iron balusters with decorative shoes, and securing them using adhesive and set screws, resulting in an updated and refreshed staircase aesthetic.

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

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