Reference Guide & Assembly Instructions

Congratulations and Thank You for your purchase!

Provided here for you is the Wahoo Rail Installation Guide for the installation of your new aluminum deck railing system. If you have any questions along the way, please don’t hesitate to call Customer Service toll-free at 877-270-9387 or visit our online Resource Library.

Please read these instructions in their entirety in order to familiarize yourself with the product and its assembly BEFORE you start your project! It is important that you  follow these steps closely to ensure the durability and safety of your deck rail system.

Tool Requirements

Tape Measure
Drill Driver
Rubber Mallet/Hammer
Work Gloves & Safety Glasses
Compound Miter Saw Or Skill Saw
Phillips/Square Drive Bit
3/8" Metal Drill Bit
#2 Square Drive Bit
T-25 Torx Bit


A: Pedestal Mount
B: Rail Post
C: Post Cap
D: Picket Rails
E: Top Rail
F: Bottom Rail
G: Fixed Rail Mount
H: Hinged Rail Mount

Mill-Finish Post Mount Installation (Surface)

Before assembling your rail kits, lay out and install the mill finish post mounts and posts

To avoid spacing the post too far from each other, keep in mind the overall width of the railing section provided for this span and the additional thickness of the rail mounting hardware. (Illustration A)

Illustration A

Measure and place center marks on the deck where the mill finish post mounts will be placed.

Place the mill finish post mounts and mark through the four mounting holes to the decking surface. Remove the mill finish post mount and pre-drill for the 3/8″ lag bolts for the post mount attachment. Using the 3/8” LAG Bolts provided secure the mill finish post mounts onto the deck. If you are installing a waterproof system (such as AridDek), seal around bolt holes with exterior-grade sealant.

*It is necessary to add additional blocking below the decking surface where the post will be installed to provide support for the mill finish post mount. (Illustration B)

Illustration B

Rail Kit Assembly Guide

Prepare a suitable working area large enough to assemble a 6’ rail section. This surface should be free of any debris that may scratch the painted rail components.

(Illustration C) *Note: Lower the torque setting on your drill to prevent “over-drilling.”

Illustration C

Remove the contents of one carton only. Arrange the rail ribbons and balusters (pickets) on the work surface with the handrail ribbon facing front. Determining post to post baluster spacing and pre-cutting the ribbons and rails may be easier prior to kit assembly. Note that the baluster mounting holes are offset and should be considered when pre-cutting the ribbons and rails. Prepare a suitable working area large enough to assemble a 6’ rail section. This surface should be free of any debris that may scratch the painted rail components.

(Illustration C) *Note: Lower the torque setting on your drill to prevent “over-drilling”.

Attach the first baluster to right end of the handrail (upper) ribbon with one screw (#10×1- 3/4” Flat Head). When using a power screwdriver, adjust the torque setting to a lower value to prevent damage to the screw head or baluster. If you do strip a screw hole, turn the baluster 180 degrees and use the opposite hole.

(Illustration D) Repeat until all balusters are installed. Verify placement of attached balusters. There should be a 3 ½” gap between each baluster.

Illustration D

Flip the assembly over so that the opposite ribbon is exposed for attachment. Fasten the bottom rail ribbon to each baluster from right to left. Attach the bottom rail cap to the bottom rail ribbon. Starting on one end, firmly squeeze the cap and the ribbon together until the cap starts to snap on. Continue squeezing or use a rubber mallet to finish completely attaching the cap to the ribbon.

(Illustration E) The bottom rail cap should be attached prior to the top rail cap. Repeat this process for the handrail cap.

Illustration E

Rail Installation

Slide the post onto the mill finish post mounts until seated. Using a level, position the post as desired. Fasten post to the mount on all four sides using the 3/8” LAG Bolts (pre-drilling these holes is required).

Make sure the screws are low enough to be covered by the decorative post collar. (Illustration F)

Illustration F

Using the proper top rail and bottom rail castings for 36” and 42” rail heights. Measure and mark the locations on your post and install the brackets using the self-tapping powder coated screws. Pre-drilling these mounting holes will help to provide better accuracy and fit.

Remove the brackets from the post and insert/fasten them onto the corresponding ends of the rail kit. Remount the assembled rail section in between the post. (cutting some spacing blocks to rest the rail section on will help to stabilize the section while reattaching).

Repeat until all rail sections and post are installed and install Post Caps. (Illustration G)

Illustration G

Stair Rail Assembly

Follow steps 1 and 2 of the Post/Surface Mount installation for the installation of the Stair Rail Posts. Once the stair post are installed, check the rise and run of the stairs to determine the proper stair rail angle. (Illustration H)

Determine the length of the top and bottom rail (consider the mounting hardware when doing this) and the desired height of the balusters. Cut the appropriate angle on both ends of the balusters and assemble to the rail ribbons. Attach the top and bottom rail cap. You can now layout the spacing for the mounting hardware on the post. (Illustration I)

The mounting hardware in the Stair Kits are hinged brackets to accommodate different stair angles. Separate the two pieces and attach one to the post and the other to the corresponding rail end. You will need to reconnect the rail section to the post by inserting the hinge pins back into the mounting brackets.

(Illustration J) It may be necessary to pinch one end of the pin with a pair of channel lock pliers to ease the installation.

Illustration H
Illustration I
Illustration J

Proper Care And Cleaning

The Finish on the Wahoo Rail Aluminum Railing is a baked on, powder coated finish. The finish is highly durable and resists UV fading. While aluminum railing is very low maintenance, light care and cleaning is recommended.

In most cases, spraying your railing with a standard garden hose will remove most of the static dirt that has accumulated. When a more determined approach is needed, use a mild detergent with a soft sponge or cloth to wipe down the railing.

Thoroughly rinse with clean water before the detergent has a chance to dry on the railing surface. You can dry the surface with a clean cloth or simply let it air dry.

***Do not use abrasive cleaners (ie: Softscrub), solvents, harsh chemicals,
pressure washers or abrasive materials to clean your railing***

Enjoy Your Wahoo Rail!

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