Cable Bullet handrail is designed to provide you with the strongest possible top rail, with the least visual obstruction to your view. The high-strength T-6061 aluminum and reinforced design allow this handrail to span 7-9 ft with minimal deflection under load! Use Cable Bullet Spacer Bars and ultra-slim Signature Series intermediate posts for the best possible balance between strength and beauty. Extend your runs, and space your more expensive, and bulky, support posts further apart without worrying about the structural integrity of your railing or the cost to your wallet.
Additionally, our top rail meets IRC guidelines for grip-size, making it not only a durable structural top rail for your deck or landing but also a seamless, modern handrail for your stairways or ramps.
In order to create a clean, continuous top rail for your deck or stairs, our handrail was designed to be easily pieced together using structural aluminum splines. These heavy-duty splines allow you to connect your handrail pieces at any point along your run, regardless of where you place your structural posts! Handrail pieces joined using structural aluminum splines do not need to be supported at the joint. As an added benefit, splines are hidden from view, so you won’t need bulky covers that sit on top of your handrail.
All handrail is sold in 93” lengths and can be cut down on-site as needed. To join corners, use Delrin plastic corner splines. For complex handrail angles, use 36" spline stock to make any custom spline necessary to meet your project specifications.
Almost all handrail will require some on-site customization. Depending on your project layout, customizing aluminum handrail may require advanced skills in measuring, cutting, and basic metalwork. If you are not comfortable with your abilities in these areas, we recommend that you consult a local contractor who can help you complete your project to your specifications.
To determine how much handrail you will need, count the total linear inches of railing you have, divide by 93, and round up. This will provide you with a rough estimate of how many handrail pieces you will need to order for your project.
Our handrail was designed to be customized to meeting your project needs on-site, so be sure you are comfortable doing the necessary metalwork and have the required tools and experience.
You should also consider that preparing and installing handrail around stairs can be complicated, as it requires advanced skills in measuring and cutting angles.
If you are not comfortable with these aspects of your project, we suggest you consult with a local builder or contractor to help you with handrail installation.
Once you have installed all structural posts, you may begin installing your handrail. You can set your Cable Bullet tensioners and run your cables, however, do not tension them until after the handrail has been secured or your posts will pull out of alignment as you tension the cables.
To avoid unnecessary waste, start by piecing together your longest continuous runs.
Always use fresh blades, quality tools, and cut slowly to avoid miscuts and ragged edges. Use a fine file to get rid of any burrs that may occur after cutting to ensure the handrail and spline will fit properly together. If you are using our powder-coated handrail, we recommend marking your cut locations with painter's tape. This way if there are any scratches or chips as a result of cutting, you can spray touch-up paint before removing the tape, creating a nice, clean edge.
Once you have determined where you will connect handrail with the splines and made all the necessary cuts, you can begin the process of connecting the pieces with the splines.
Use structural aluminum splines on all continuous level runs. Delrin plastic corner splines are available for 90-degree angles. Use the Delrin spline stock to cut and join custom splines for complex irregular angles. Custom spline pieces can be joined with deck screws. When working on complex handrail transition angles it is best to start by joining your smallest pieces first and working your way out.
You will need a rubber mallet or dead-blow hammer to properly set your splines. Our handrail is manufactured with inner channels that slide into the splines to connect the two pieces. They are designed to be a tight fit, so you shouldn’t need additional methods to secure them. However, should the need arise, you can counter-sink a sheet metal screw through the underside of your handrail into the spline.
Cable Bullet’s handrail is designed for use with our Signature Series Posts. Use the ¼” Spanner Nut Bit to loosen the two threaded pins on either side of the stainless steel post top. Once your handrail is set in place, mark and drill pilot holes for each top mount (if you are using #8 - 3/4" stainless steel sheet metal screws, drill a 5/32" pilot hole). Secure the handrail, then tighten the threaded pins.
Note: To ease the installation of the handrail you may detach the u-shaped top-mounting bracket from the post top completely by removing both threaded pins. Detaching and installing the top-mounting bracket is especially helpful when installing a handrail on sloping runs, or where spacing is tight.
Once you have installed the handrail onto the posts, you can install the end caps. Our end caps are designed to be a tight fit, so it should hold fine, but we recommend using a construction adhesive/epoxy to ensure it remains secure over time.
After installation, if you notice any scratches on your flat black powder coat handrail or metal posts, we recommend using a touch-up paint to correct them.
Mill finish has an industrial look and may include cosmetic, surface-level scratches from the manufacturing process. Mill finish pieces are bare aluminum to allow for custom powder applications, or brushing. For a brushed aluminum finish, use Scotch Brite™ very fine or medium pads.
Once your handrail has been installed you are free to complete the Cable Bullet tensioner installation.
|Color:||Flat Black or Mill Finish (Bare Aluminum)|
|Material:||Type 6061 Aluminum|
|Coating:||Powder Coat, TCI 9030-90922 SD "Super Durable" FLAT BLACK|
|Wall Thickness:||0.225" Sides, 0.225" top/bottom|