April 2008 - Endurance Vinyl Railing Install Steps
Original Rail Series - Level Rail Steps

STEP 1:
Prepare all posts and mounting surfaces before installation.

STEP 2:
Establish the level placement of the lower rail so that there is no more than a 4" space* from the bottom of the rail to the standing surface (Fig. 1). Mark the mounting surfaces at this dimension, minus 3/4" to determine the placement of the mounting brackets for the bottom rail.

Tip:
Standard Original Rail measures 36" in height with a 2" space below the bottom rail. Use 2" blocks to establish bottom rail height (Fig. 2).

STEP 3:
Place the Bottom Rail across the opening where it is to be installed (Fig. 3). Measure from the mounting surface to the first baluster hole on each end (Fig. 4), and adjust until these dimensions are equal.

Trace the post onto the bottom rail and mark 1/8" short at each end to allow for expansion (Fig. 5).

Tip:
If all of your mounting surfaces are plumb, transfer your measurements and baluster layout from the bottom rail to the top rail (Fig. 6).

NOTE: A minimum of 1" from the edge of the first baluster to the end of the rail is necessary to accommodate the mounting brackets.

STEP 4:
Cut each end of the rail at the measurement determined in Step 3 (Fig. 7).

Tip:
If using a power saw, a carbide tip blade of at least 60 teeth is recommended.

STEP 5:
Place a Bottom Mounting Bracket on each end of the Bottom Rail, flat side should face the mounting surface (Fig.8). Place on the marks determined in Step 2. Pre-drill the holes (Fig. 9) for the mounting brackets to avoid stripping the stainless steel screws, and secure in place (Fig. 10).

NOTE: The looped part of the aluminum P-channel must be facing away (down) from the baluster holes while the flat side of the P-channel must be facing the outside of the deck when mounted.  Repeat Steps 3 through 5 for each rail section.

STEP 6:
Insert a baluster in each rout of the bottom rail (Fig. 11). NOTE: Each kit contains 2 crimped balusters, space them evenly in each section.

STEP 7:
Return to the first rail section and repeat Steps 3 and 4. Size and cut each top rail.

STEP 8:
Place a T-shaped mounting bracket on each end of the top rail, so the flat side faces the mounting surface. Slide the bracket back past the first baluster rout (Fig. 12). Make sure that the aluminum T-channel is flush with the end of the vinyl top rail. Use a 7/32" drill bit to drill through both ends of the top rail and aluminum Tchannel. The hole should be 5/16" from the end and 7/16" from the bottom of the rail. Place an aluminum retaining pin through the hole. Slide the bracket over the dowel to the end of the rail (Fig. 13).

STEP 9:
Beginning at one end of the rail section, (Fig. 14) insert each baluster installed in Step 6 into the corresponding rout in the top rail. To allow for baluster expansion, raise the top rail approximately 1/8". Pre-drill the holes (Fig. 15) for the mounting brackets to avoid stripping the stainless steel screws, and secure in place (Fig. 16). Repeat Steps 6 through 8 for each rail section.

STEP 10:
Check entire installation for accuracy before snapping Screw Head Covers (Fig. 17) into place.