Cut Your Balusters

What happens in this clip

Iron balusters are typically supplied longer than needed (e.g., 44 inches) and require cutting to fit your specific railing. Measure the distance from the bottom of the handrail to the top of the bottom trim. Add 1 1/4 inches to this measurement to determine the total length for your baluster. This extra length allows the baluster to slide into both the handrail and the bottom trim. Use an angle grinder to cut the bottom of each baluster to the calculated length. After cutting, use the angle grinder to smooth any burrs or stray metal shapings, as these can scratch your trim or handrail during installation.

Goal: Trim balusters to the precise length required for installation.

What's used

Tools

• Angle Grinder Milwaukee Fuel
• Miter saw with metal cutting blade
• Gloves
• Hearing Protection
• Safety Glasses
• Tape Measure

About the full video

This DIY project guides you through installing iron balusters, replacing an existing railing system. It covers removing old spindles and handrails, preparing new handrails, measuring and pre-drilling holes for balusters, cutting balusters to precise lengths, and finally installing them using epoxy and securing the decorative shoes.

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 (this video)
   • 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