My Deck Rail project

[REP]

I've got a 20 year old deck that I've sanded and stained, and all I have left to do is put up railing (ground level), since the old wood balusters were just not salvagable. I thought about something like this:

http://homedepot.flyerservices.com/cached_images/Products/large/HD_PR02A8_139_FW13_07_280837_0001_img4.jpg

However, I have decided to buy my own 2x4's and use a drill press since it's about 25% of the cost of the Home Depot pre-drilled wood. I also purchased the $0.37 metal clips and spray painted them black (Tremclad galvanized steal primer and Tremclad black). This was MUCH cheaper then the $5.72 clips that come with the Home Depot fence package especially when I need 30 of them.

Finally, the reason I'm asking here.... The 36" aluminum balusters are 40.00 for 15... I need about 90 of them or about $240.00. I'm certain there is a cheaper alternative since they are aluminum metal pipes that I would be happy to buy, cut and paint, but I did not find anything sufficient at HD.

I thought I would solicit some innovative minds to help me with this little problem, and to share my money saving strategy.

Thanks for your help.

[3weddings]

Since you're willing to paint it, how about conduit?

[REP]

I'll check out the conduit, but I was hoping for something Metal. How would copper plumbing work? Would it survive outdoors with a good coat of Tremclad? It also needs to be strong enought to withstand the day to day dings of a deck.

[UberDave]

have you looked at Metal Supermarkets?
http://www.metalsupermarkets.com/

I'm not sure what their prices are like but they'll cut to length and I'm sure prices are better than HD. Painting them yourself is going to suck though.

[hyperactiveme]

I'll check out the conduit, but I was hoping for something Metal. How would copper plumbing work? Would it survive outdoors with a good coat of Tremclad? It also needs to be strong enought to withstand the day to day dings of a deck.

it would work 100%. I would leave the copper, copper. Waste to paint it. However you need to see if it is any cheaper.

[armbrusts]

I'll check out the conduit, but I was hoping for something Metal. How would copper plumbing work? Would it survive outdoors with a good coat of Tremclad? It also needs to be strong enought to withstand the day to day dings of a deck.

Isn't there metal conduit? What about gas pipe?

[mork]

Copper pipe will be expensive I think. People do use it for decorative balusters in deck rail projects a lot. Without a coating it will get kind of greenish with time, but that is usually desired.

Metal conduit will be your best bet cost-wise think. I bought a 10ft long 3/4" steel conduit for somewhere around $7 or so at Home Depot not too long ago..

I'm planning a deck railing project soon as well so will be interested in hearing your results. I am currently leaning towards using P/T lumber.. 4x4 posts, 2x4 runners and then using something like this for balusters:
http://www.deckorators.com/images/baroqueMain.jpg

[REP]

There are some great suggestions here. I'll go on the hunt for some materials this weekend. I'll certainly provide everyone with an update once I get to the work.

I would have liked to have just used copper without paint, but my wife had me invest in black patio furniture last month, so the balusters must be black as well.

[curls00]

I actually used the Stiles balusters (from your flyer clipping pic) and LOVE the result. I only opted to use the balusters and used my own wood and a 3/4" spade bit (no drill press -- no need as the drill has a bubble level on it). I didn't use the tiny plastic 'hats' that protect the ends of the aluminum from the PT wood, but thats no biggie to me, since finding the 7/8" spade bit was impossible and without it the hats wouldn't fit.

The balusters are fairly expensive but I didn't want plain wooden balusters, nor did I want anything that could ding my childrens' heads (like the metal straps from mork's post), so I went with the Stiles ones and really couldn't be happier - they were simple to use, look great, and overall they weren't too pricey.

I didn't use their clips to hold the rails up, either - I hid the decking screws by toe-screwing and you'd never see a screw head on the railing of my deck unless you were underneath looking up. :)

[mork]

I did my railing today. I stumbled into a fantastic deal at a local building center clearing out their balusters.

Here's how it turned out:
http://i392.photobucket.com/albums/pp3/mork571/yard/railing01.jpg