Installing an Aluminum Top Rail with Self-Tapping Screws
Use this method to fasten an Inline Design Black Matte 6005A-T61 aluminum top rail to the post saddles with the recommended #10 × 3/4 in. 410 stainless-steel Phillips truss-head self-drilling screws. With the specified screw, do not drill a pilot hole; the screw's drilling point is designed to penetrate the aluminum wall and form its own threads.
Application: Current Inline Design black aluminum top rail to post saddle only. These screws are not intended for anchoring railing posts to a deck, concrete, framing, or another supporting structure.
Use the Correct Screw
Black Aluminum Railing
#10 × 3/4 in. black-finish 410 stainless-steel Phillips truss-head screw with a self-drilling point
View recommended black screwImportant: “Self-tapping” does not always mean “self-drilling.” This no-pilot-hole method applies only to a screw with an actual drilling point suitable for metal. If an alternate screw does not have a drilling point, do not use these instructions; follow that fastener manufacturer's pilot-hole requirements.
Tools and Materials
Installation Procedure
Dry-Fit the Top Rail
Place the aluminum top rail on the post saddles. Confirm that the posts are plumb and aligned and that the rail is fully seated on every saddle.
Verify the Complete Run
Check all corners, joints, transitions, and end overhangs. Hold the rail securely in its final position before installing any screws.
Position the Screw
Use the existing hole in the saddle as the guide. Insert the recommended screw and hold it perpendicular to the lower wall of the top rail. Do not pre-drill the aluminum.
Start at Low Speed
Using a variable-speed drill/driver and a #2 Phillips bit, apply steady pressure and drive at low speed until the drilling point penetrates the lower aluminum wall and the threads begin to engage.
Seat the Screw
Reduce pressure as the screw seats. Stop as soon as the truss head is firmly against the saddle. The screw should be snug without deforming the saddle or stripping the aluminum threads.
Clean and Inspect
Remove all aluminum chips from the saddle, rail, and nearby finished surfaces with a soft cloth or nonabrasive brush. Confirm that the rail is tight and the screw does not spin freely.
Critical Installation Requirements
- Do not use the 11/64 in. stainless-steel spot-drill specification on the aluminum top rail.
- Do not pre-drill when using the recommended self-drilling screw.
- Do not drill through the upper wall of the top rail.
- Do not use an impact driver.
- Do not overtighten; aluminum threads can strip if the screw is driven after it is seated.
- Keep the drill chuck away from the painted rail surface.
- Remove all aluminum chips immediately after installation.
Installing a Stainless-Steel Top Rail?
Stainless-steel tubing requires a different procedure, including an 11/64 in. spot-drilled hole and cutting fluid.
View the stainless-steel top-rail instructionsWear appropriate eye and hand protection when drilling or installing metal components. Installation conditions and substituted fasteners can affect performance. The installer is responsible for confirming that the railing, post anchorage, supporting construction, and completed installation comply with applicable project requirements and building codes.