| 1 INSTALLATION GUIDE
| 2 TABLE OF CONTENTS. RailFX® Railing Overview....................................................3. Rail Profiles ........................................................................ 4 . Railing Component Guide .............................................5-11. Surface Mount Post Installation ...................................12-13. Single Corner Post Installation ..........................................14. . Direct to Fascia Mount .................................................19-23 . Surface Mount Stair End Post ......................................24-26 . Surface Mount Stair Intermediate Post........................27-28. RFX100/250 Top Rail Installation ......................................29. RFX200 Top Stair Connector Installation.......................30-31. RFX400 Top Stair Connector Installation ......................32-33. RFX200/300 Top Rail for Level Applications .................34-35. RFX200/300 Top Rail for Stair Applications… ...................36. RFX400 Top Rail for Level Applications ........................37-38. 224 Cable Installation......................................................39-40. Flex Cable Installation ....................................................41-45. Basic 200/250 Fascia Layout ...............................................46.. Basic 200/250 Surface Layout ..............................................47
3| RAILFX® RAILING OVERVIEW RailFX® Aluminum Rail and Cable System have been designed, engineered, and tested specifically for a cable, picket or glass application rail system. The aluminum framework and choice of infill options allows for railings to be lightweight, while still retaining exceptional durability. Rail Guidelines To comply with engineering and testing, posts must be spaced no more than 60" on center. Cables are spaced 3-3/16" on center to keep cable from deflecting beyond 4" to meet code. Cable can either terminate at the corner or run continuously through corners. Single corner posts can be used with cable running through the corner. Top rail is required for all railing installations.
4 | RAIL PROFILES RFX100 RFX300 RFX200 RFX400 RFX250 RFXADA Special Order Special Order Special Order
| 5 COMPONENT GUIDE Corner Post 362SC (Surface 200/400 Rail) 362FC (Fascia 200/400 Rail) 366SC (Surface 250 Rail) End Post 362SE (Surface 200/400 Rail) 362FE (Fascia 200/400 Rail) 366SE (Surface 250 Rail) *Stair End Post 452US (10 Hole) Intermediate Post 362SI (Surface 200/400 Rail) 362FI (Fascia 200/400 Rail) 366SI (Surface 250 Rail) *Stair Intermediate Post 452UI (10 Hole) *Bases ordered seperately and post cut to length on site
6| END CAPS AND CORNER BRACKETS RFX 100 End Cap Special Order RFX 300 End Cap Special Order RFX 200 End Cap Item# 0112 RFX 400 End Cap Item# 0124 RFX 250 End Cap Item# 0114 RFX ADA End Cap Special Order
| 7 END CAPS AND CORNER BRACKETS (CONTINUED) RFX 200 Extended End Cap Item# 0113 RFX 200 Stair Corner Connector Item# 0125 RFX 300 Extended End Cap Special Order RFX 400 Stair Corner Connector Item# 0126 RFX 400 Extended End Cap Item# 0127
8 | RFX 200 / 300 Top Rail Splice Item# 0115 RFX 400 Top Rail Splice Item# 0413 RFX 200 / 300 Top Rail Hinged Splice Item# 0122 RFX 400 Top Rail Hinged Splice Item# 0123 SPLICES / CONNECTORS
| 9 SPLICES / CONNECTORS RFX 100 / 250 Top Rail Splice Item# 011812 RFX ADA Female to Male Corner *Available in 90 degrees RFX 100 / 250 Top Rail Over The Post Fitting Item# 0412 RFX 100 / 250 Top Rail Connecting Block (RCB) Item# 0118 Special Order RFX ADA Male to Male Corner *Available in 33, 36 and 90 degrees Special Order RFX ADA Rail Splice Special Order
10 | HARDWARE / ACCESSORIES 5x5 RFX Base Plate RFX 135 Degree Fascia Bracket RFX Straight Fascia Bracket 5x5 RFX Slotted Base Plate RFX Post Skirt (Optional) RFX Double Outside Corner Hinged Fascia Bracket 3x7 RFX Slotted Base Plate RFX Post Cap RFX Single Outside Corner Fascia Bracket 3x5 RFX Base Plate RFX 135 Post Cap RFX Single Inside Corner Fascia Bracket Item# 0425 Item# 0414 Item# 0422 Special Order Special Order Item# 0415 Item# 0423 Item# 0424 Special Order Item# 0120 Special Order Item# 0410
| 11 HARDWARE / ACCESSORIES RFX ADA Mount T-40 Self Tapping Stainless Steel Screws 3/8" Stainless Steel Cup Washer 5.5" x 3/8" Stainless Steel Lag Bolt Push Lock Release Key RFX System Install Kit #10 – ¾" Screw #14 – 1" Fascia Bracket Screw Vinyl Bolt Cap Internal Post Stiffener 1/8" Cable Cutter (Optional) 7.5" x 3/8" Stainless Steel Lag Bolt Included with bracket Special Order Included with post Included with post Item# 3066 Item# 0417 Item# 0419 Item# 0910 (100pk) Item# 0413 Item# 3068 Item# 3053-224 Included with base plate kit
12 | Materials included for installation: SURFACE MOUNT POST INSTALLATION For 36"/42" RailFX® Aluminum Railing and Cable System It is the responsibility of the installer to meet all code and safety requirements, and to obtain all required building permits. The deck and railing installer should determine and implement appropriate techniques for each installation situation. RailFX® or its distributors shall not be held liable for improper or unsafe installations. Determine appropriate layout and post spacing- Maximum post spacing is 60" on center. Ensure that proper blocking is in place prior to mounting post. 5.5"/7.5" lag must be fully embedded into blocking. • Wood blocking must be constructed with treated dimensional lumber • Secure wood blocking to deck frame on all four sides – using #10-3-1/2" deck screws • Wood blocking must be constructed with a minimum thickness of 1-1/2" • Base plate holes MUST be positioned a minimum ½" from the edge of the deck board • Use only 3/8" diameter lag screws to attach post • Secure each post with four bolts
13| SURFACE MOUNT POST INSTALLATION For 36"/42" RailFX® Aluminum Railing and Cable System Step 1 Determine location of post and mark hole locations. Step 4 Ensure post is plumb. If not, adjust as needed utilizing composite shims. Tighten fasteners and ensure proper engagement of lags. Step 2 Remove post and pre-drill pilot holes to accept 3/8" diameter lag bolt. Step 5a Press bolt caps onto cup washer to finish post. Step 3 Install cup washer under head of each fastener and drive fastener into blocking. Step 5b Finished Installation. (Unless using post skirt). Step 6a Install 2 piece post skirt (optional). Secure with 2 screws (included). Step 6b Finished Installation.
|14 SINGLE CORNER POST INSTALLATION RFX200/300 TOP RAIL – MITER, SPLICE & POST ATTACHMENT Step 1: Bend and Insert Cable Create a bend in cable to allow for easier insertion into post. Do not fray cable end. Step 4: Insert Conduit Insert conduit into post and align to inside corner. Pull cables tight to conduit. Step 2: Run Cable Insert and pull through 1ʼ on all cables on post. Step 1: Miter Top Rail Miter top rails to create a 90 degree corner and slide splice into each end of the rail. Step 3: Create a Loop Push cable back into post creating a loop. Step 2: 90 Degree Splice Install Using 8 each screws, secure splice into top rail from the underside of the rail. Ensure screws do not interfere with post. Step 3: Single Corner Post Once top rail is secured with a splice, it can be placed onto the post. Use 2 each screws to attach top rail to post.
15 | Materials included for installation: FASCIA POST WITH BRACKET FASCIA MOUNT END POST WITH BRACKET It is the responsibility of the installer to meet all code and safety requirements, and to obtain all required building permits. The deck and railing installer should determine and implement appropriate techniques to each installation. RailFX® or its distributors shall not be held liable for improper or unsafe installations. Determine appropriate layout and post spacing – Maximum post spacing of 60" on center. Ensure that proper blocking is in place before mounting post. Step 1 Determine location of end post fascia bracket. Ensure bracket is plumb, mark holes, remove bracket and drill pilot holes to accept 3/8" diameter lag bolt. Step 2 Install cup washer under head of each fastener and drive fastener loosely into blocking. Step 3 Ensure bracket is plumb, adjust as needed. Tighten fasteners and ensure proper engagement into blocking.
| 16 FASCIA POST WITH BRACKET FASCIA MOUNT END POST WITH BRACKET Step 4 Install fascia end bracket at opposite end. Measure down from deck boards the same distance as the first bracket. Step 7 Insert 2 each post stiffeners into end post parallel to pre- drilled cable fitting holes as shown. Carefully install post with stiffeners into mounted fascia bracket. Step 5 Insert top of post into bracket and mark bottom of post at 34-1/2" above deck surface to meet 36" rail height requirements. Step 8 Plumb post and secure into bracket by installing 4 each self-drilling #1/4 x 1" screws. Step 9 Install nylon bolt cap covers for a finished look. Step 6 Cut post end using a sharp carbide 80 tooth blade on a miter saw.
17 | Materials included for installation: FASCIA POST WITH BRACKET FASCIA MOUNT INTERMEDIATE POST WITH BRACKET It is the responsibility of the installer to meet all code and safety requirements, and to obtain all required building permits. The deck and railing installer should determine and implement appropriate techniques to each installation. RailFX® or its distributors shall not be held liable for improper or unsafe installations. Determine appropriate layout and post spacing – Maximum post spacing of 60" on center. Ensure that proper blocking is in place before mounting post. Step 1 End post brackets must be installed prior to intermediate bracket placement. A level string is used to place intermediate bracket, ensuring all brackets are on same plane. Step 2 Determine location of fascia bracket. Ensure bracket is level, mark holes, remove bracket and drill pilot holes to accept 3/8" diameter lag bolt. Step 3 Install cup washer under head of each fastener and drive fastener loosely into blocking.
INSTALLATION GUIDE: RAILFX® CUSTOM RAILING SYSTEMS | 18 FASCIA POST WITH BRACKET FASCIA MOUNT INTERMEDIATE POST WITH BRACKET Step 4 Ensure bracket is plumb, adjust as needed. Tighten fasteners and ensure proper engagement into blocking. Step 7 Plumb post and secure into bracket by installing 4 each self-drilling #1/4 x 1" screws. Step 5 End posts must be installed prior to intermediate post placement. A level string can be used to properly align all intermediate posts. Posts must be 34-1/2" above deck board for a 36" rail height. Step 8 Install nylon bolt cap covers for a finished look. Step 6 Insert top of post into fascia bracket and mark where string line intersects. Cut post end using a sharp carbide 80 tooth blade on a miter saw.
19 | Materials included for installation: DIRECT TO FASCIA MOUNT FASCIA MOUNT END POST WITHOUT BRACKET It is the responsibility of the installer to meet all code and safety requirements, and to obtain all required building permits. The deck and railing installer should determine and implement appropriate techniques to each installation. RailFX® or its distributors shall not be held liable for improper or unsafe installations. Determine appropriate layout and post spacing – Maximum post spacing of 60” on center. Ensure that proper blocking is in place before mounting post. Step 1 Determine location of end post. (Max. post spacing of 60" on center) Posts must be 34-1/2" above deck board for a 36" rail height. Step 2 Mark post at deck height to use as a reference point. Step 3 From the mark created, measure down to first hole and mark. The second hole must be at least 4-1/2" down from the first hole. After marking, drill holes. Holes should be marked and drilled separately. If needed, trim excess off end of post.
| 20 DIRECT TO FASCIA MOUNT FASCIA MOUNT END POST WITHOUT BRACKET Step 4 With post laying horizontally, slide 2 each 34" post stiffeners into existing channels parallel to pre- drilled cable holes. Stiffeners provide necessary rigidity for posts. Step 4c This cross section looking up from the bottom of the post shows how the stiffeners crisscross inside the post. Step 4a Then, slide 2 each 10" post stiffeners into other channels perpendicular to pre-drilled cable holes. Stiffeners provide support for posts. Step 5 Confirm location of fascia post. (Max. post spacing 60" on center). Mark holes, remove post and drill pilot holes to accept 3/8" lag bolts. Step 6 Install cup washer under head of fastener and drive fastener loosely into blocking. Step 4b Install threaded inserts into opposite corners of post. Then install direct fascia post cap using 2 each provided screws.
21 | DIRECT TO FASCIA MOUNT FASCIA MOUNT END POST WITHOUT BRACKET Step 7 Plumb post, adjust as needed. Tighten fasteners and ensure proper engagement into blocking. Step 8 Install nylon bolt cap covers for a finished look.
| 22 Materials included for installation: DIRECT TO FASCIA MOUNT FASCIA MOUNT INTERMEDIATE POST WITHOUT BRACKET It is the responsibility of the installer to meet all code and safety requirements, and to obtain all required building permits. The deck and railing installer should determine and implement appropriate techniques to each installation. RailFX® or its distributors shall not be held liable for improper or unsafe installations. Determine appropriate layout and post spacing – Maximum post spacing of 60" on center. Ensure that proper blocking is in place before mounting post. Step 1 End posts must be installed prior to intermediate post placement. A level string can be used to properly align all intermediate posts. Posts must be 34-1/2" above deck board for a 36" rail height. Step 2 Mark post at deck height to use as a reference point. Step 3 From the mark created, measure down to first hole and mark. The second hole must be at least 4-1/2" down from the first hole. After marking, drill holes. Holes should be marked and drilled separately. If needed, trim excess off end of post.
23 | DIRECT TO FASCIA MOUNT FASCIA MOUNT INTERMEDIATE POST WITHOUT BRACKET Step 7 Plumb post, adjust as needed. Tighten fasteners and ensure proper engagement into blocking. Step 4 Slide 2 each 10" post stiffeners into other channels perpendicular to pre-drilled cable holes. Stiffeners provide support for posts. If using picket infill, place post stiffeners perpendicular to rail connecting block holes. Step 8 Install nylon bolt cap covers for a finished look. Step 5 Confirm location of fascia post. (Max. post spacing 60" on center). Mark holes, remove post and drill pilot holes to accept 3/8" lag bolts. Step 6 Install cup washer under head of fastener and drive fastener loosely into blocking.
| 24 NOTE: Post comes long on top and bottom and will require trimming prior to installation. SURFACE MOUNT STAIR END POST Step 2 Measure desired height of post and add 3/8" to accommodate base plate. Step 1 Temporarily fasten base plate to post using 2 screws. Step 3 Determine location of bottom end post and mark base plate holes. Step 4 Temporarily fasten post.
25| SURFACE MOUNT STAIR END POST Step 4 Insert cable into first hole of top end post (previously mounted) and pull tightly along side the bottom end post. Ensure that cable is evenly spaced above the nose of the treads, then mark the bottom end post, using masking tape, where the cable intersects the post. Step 5 Measure distance (Distance “X”) from the mark made in Step 4 to the top of the base plate. Step 6 Use Distance “X” from Step 5 and measure down from the center of the first hole (closest to the tread).
| 26 SURFACE MOUNT STAIR END POST Step 7 Remove post from tread and remove base plate from post before cutting. Then, cut post at marked cut line from Step 6. Step 10 Attach post to surface. Step 8 Re-attach base plate to bottom of cut post with all 4 screws. (Use beeswax for easier install). Step 11 Finished post installation. Bolt caps (shown) or post skirt. Step 9 Before final post attachment, the top of the post will need to be cut accordingly, so cable is 3-1/2" or less from top rail.
27| NOTE: Post comes long on top and bottom and will require trimming prior to installation. SURFACE MOUNT STAIR INTERMEDIATE POST Step 1 Temporarily install base plate with 2 screws. Step 2 Determine location of bottom end post and mark base plate holes. Step 3 Temporarily fasten post. Step 4 Insert cable into first hole of top end post (previously mounted) and pull tightly along side the bottom end post. Ensure that cable is evenly spaced above the nose of the treads, then mark the bottom end post, using masking tape, where the cable intersects the post.
| 28 SURFACE MOUNT STAIR INTERMEDIATE POST Step 8 Re-attach base plate to bottom of cut post with all 4 screws. (Use beeswax for easier install). Step 9 Before final post attachment, the top of the post will need to be cut accordingly, so cable is 3-1/2" or less from top rail. NOTE: Ensure that top rail is 34" above stair. Step 7 Remove post from tread and remove base plate from post before cutting. Then, cut post at marked cut line from Step 6. Step 5 Measure distance (Distance “X”) from the mark made in Step 4 to the top of the base plate. Step 6 Use Distance “X” from Step 5 and measure down from the center of the first hole (closest to the tread). Step 10 Attach post to surface. Step 11 Finished post installation. Bolt caps (Shown) or post skirt.
29| RFX100/250 TOP RAIL INSTALLATION Rail Connecting Block Measure 3-1/2" from middle of top hole to determine install location of RCB. Secure fitting in place with 2 each screws. Cut top of post to desired height. NOTE: Ensure that top rail is 34" above stairs. RFX100/250 Infill Snip RCB to allow Infill to be snapped on for a finished look. NOTE: Install prior to tensioning the cables. Cutting Top Rail Measure the distance and angle needed for top rail to fit between posts. Cut top rail using a saw. Install Post Cap Install post cap. Use adhesive to secure cap to post. Attaching Top Rail Slide top rail over top of RCB and secure with 2 each screws one on each side.
30 | RFX200 TOP RAIL STAIR CORNER CONNECTOR INSTALLATION Rail Connecting Block Align bottom of Rail Connecting Block (RCB) with bottom of RFX200 Stair Corner Connector (RFX200 SCC). Predrill RFX200 SCC with a 5/23" drill once RCB is centered on RFX200SCC. Attach RFX200SCC to Top Rail Attach RFX200SCC to Top Rail using 4 provided screws. Grooves in post help center RFX200SCC. Fully seat #2 square drive screws once connector is installed. Cutting RCB Using tin snips, clip back edges of RCB to match angle of stairs. Install Stair Top Rail Cut Top Rail to angle of stairs. Place Top Rail onto RCB to ensure correct fit. Install Stair Top Rail Secure Top Rail to RCB using self drilling screw on each side. NOTE: Screws to be offset to avoid collision on rail. Attaching RCB to RFX200SCC Using provided #2 square drive screws, attach RCB to RFX200SCC. NOTE: Do not fully seat screws on this step.
| 31 RFX200 TOP RAIL STAIR STRAIGHT CONNECTOR INSTALLATION Rail Connecting Block Align bottom of Rail Connecting Block (RCB) with bottom of RFX200 Extended End Cap (RFX200 EEC). Predrill RFX200 EEC with a 5/23" drill once RCB is centered on RFX200EEC. Attach RCB to RFX200EEC Attach RCB using provided #2 square drive screws. NOTE: Follow same steps for RFX300 Top Rail. Cutting RCB Using tin snips, clip back edges of RCB to match angle of stairs. Install Stair Top Rail Secure Top Rail to RCB using self drilling screw on each side. NOTE: Screws to be offset to avoid collision on rail. Install Stair Top Rail Cut Top Rail to angle of stairs. Place Top Rail onto RCB to ensure correct fit. Attaching RFX200EEC to RFX200 Top Rail Using provided 2 screws, attach RFX200EEC to RFX200 Top Rail. Once attached, use 5/32" drill to predrill post.
32 | RFX400 TOP RAIL STAIR CORNER CONNECTOR INSTALLATION Stair Corner Connector Attach RFX 400 Stair Corner Connector (RFX400SCC) to post. Grooves allow centering of bracket. Cut Top Rail Cut Top Rail to match stair angle. Tip of rail must be cut 5/16" down to fit under wood top rail. Cutting RCB Using tin snips, clip back edges of RCB to match angle of stairs. Install Stair Top Rail Place Top Rail onto RCB to ensure correct fit. Install Stair Top Rail Secure Top Rail to RCB using self drilling screw on each side. NOTE: Screws to be offset to avoid collision on rail. Attaching RCB to RFX400SCC Measure down 1-3/4" from top of RFX400SCC and mark a line. Using provided #2 square drive screws, attach RCB to RFX400SCC on marked line.
| 33 RFX400 TOP RAIL STAIR STRAIGHT CONNECTOR INSTALLATION Attach End Plate Attach RFX 400 Extended End Cap (RFX400EEC) using provided screws. Cut Stair Top Rail Cut Top Rail to angle of stairs. Tip of rail must be cut 5/16" down to fit under wood top rail. Attach RCB to RFX200EEC Attach RCB using provided #2 square drive screws. Cutting RCB Using tin snips, clip back edges of RCB to match angle of stairs. Install Stair Top Rail Place Top Rail onto RCB to ensure correct fit. Install Stair Top Rail Secure Top Rail to RCB using self drilling screw on each side. Drill RCB Alignment Holes Measure 1-3/4” from top of RFX400EEC and mark a line. Align RCB holes with line and center RCB. Drill RFX400EEC with 5/32” drill bit.
34 | RFX200/300 TOP RAIL FOR LEVEL APPLICATIONS Attaching to End Post Rail slides over top of post and attaches with 2 each screws. RFX200/300 Level Splice - 1 Level splice slides into each end of the rail. Splice is acceptable between posts or over posts. Attaching End Cap End cap goes on open end of top rail. Use 2 each included self- tapping screws to attach to top rail. End cap must be installed first if ending against a wall. RFX200/300 Level Splice - 2 Use 8 each self-tapping screws to secure splice into rail from the underside. Option to Splice Over a Post Splice must be installed into rail and then rail mounts to post. Secure rail with 4 each screws. Attaching to Intermediate Post Rail slides over top of post and attaches with 2 each screws. 1 screw on each side.
| 35 RFX200/300 TOP RAIL FOR LEVEL APPLICATIONS RFX200/300 TOP RAIL FOR LEVEL APPLICATIONS NOTE: Standard end cap can also be used if desired. Angled Splice Splices are also used to attach corner rails. Angles include 45, 90 and custom degrees. RFX200/300 Terminating into Post - 1 Drill 2 holes through the end cap for screws. RFX200/300 – Flat In Cut flat infill to length and snap into bottom side of to rail. NOTE: Install prior to tensioning the cables. RFX200/300 Terminating into Post - 2 Use 2 each wood screws to attach end cap to top rail then attach rail to column using two each screws.
36 | RFX200/300 TOP RAIL FOR STAIR APPLICATIONS RFX200/300 – Stair Splice Bend splice to the correct angle of the stairs and secure splice into place with 8 each screws. RFX200/300 Stair Intermediate Post Cut post at the angle of the stairs. Rail slides over top of post and attaches with 2 each screws. 1 screw per side. Stair Splice – Application 1 Example of rail mitered down the stairs in a continuous line. RFX200/300 Level Splice - 2 Cut post at the angle of the stairs. Rail slides over top of post and attaches with 2 each screws. 1 screw per side. Stair Splice – Application 2 Example of rail mitered down the stairs in with a 90 degree turn. NOTE: • RFX200/300 does not qualify as a graspable rail down the stairway. A secondary handrail must be used (ADA Sub-Rail) or RFX100/250 top rail can be used. • Painting the ends of the railing that has been cut will help prevent oxidation. • Railing must be cut square to allow end cap to securely attach to rail.
37 | RFX400 TOP RAIL FOR LEVEL APPLICATIONS RFX400 Top Rail Allows for a wood / composite cap to be attached to the RailFX rail system. Cap can be screwed directly to top rail or dadoed out. Attaching to Intermediate Post Rail slides over top of post and attaches with 2 each screws. 1 screw on each side. Attaching to End Post Top rail slides over top of post and attaches with 2 each screws. 1 screw on each side. Attaching to Intermediate Post Wood / Composite cap attaches to RFX400 top rail by screws from the bottom side. Screwing from Bottom Side Wood / Composite cap attaches to RFX400 top rail by customer provided screws from the bottom side. Attach cap before installing flat infill. Attaching to End Post Wood / Composite cap attaches to RFX400 top rail by screws from the bottom side.
| 38 RFX400 TOP RAIL FOR LEVEL APPLICATIONS Straight Splice Option 1 Both top rails slide over top of post and attach with screws. 1 screw on each side. (Total of 4 each screws). Angle Splice Splice must be secured into place with 8 each screws from underside. (Top rail must be mitered). Straight Splice Option 2 Splice must be secured into place with 8 each screws from underside. Splice is made from a cut piece of Internal Post Stiffener. RFX400 – Flat Infill Cut flat infill to length and snap into bottom side of top rail. NOTE: Install prior to tensioning the cables. Straight Splice Option 3 Use wood / Composite as splice to connect rails together where RFX400 rails meet between posts.
| 39 CABLE INSTALLATION GUIDE RailFX® LOW PROFILE CABLE KIT INSTALLATION INSTRUCTIONS 1. Install the tensioning end first with the 2-3/8" long receiver. 2. Slip the Delrin washer over the body of the receiver and insert the receiver into the post. 3. Start the threaded stud attached to the cable into the receiver and turn 3 complete turns. This will thread about half the stud into the receiver. 4. Run the bare end of the cable through all your intermediate posts and through the end post where the pull-lock fitting will be installed. 5. Slip the Delrin washer over the body of the pull-lock fitting prior to running cable through fitting. 6. Push the cable into the hole in front of the pull-lock fitting. Twist the cable in the right-hand direction as it is being pushed. If the cable begins to “unravel” it is being rotated the wrong way. Push the cable until it is through the fitting. 7. Once the cable is through the fitting, pull cable while holding the pull-lock fitting firmly in the hole on the post. Hold the fitting in one hand while pulling the cable through as tightly as possible. NOTE: Longer runs of cable and cables that go around corners may need to be pretensioned. Low Profile Kit Contents Pull-Lock® Fitting with cap 1/8" 1x19 stainless steel cable Pre-attached swaging stud Invisiware® Receiver Delrin® washers for use with metal posts Stainless Steel washers for use with wood posts NOTE: Parts must be kept clean and free of debris before installation for best results.
40 | CABLE INSTALLATION GUIDE RailFX® LOW PROFILE CABLE KIT INSTALLATION INSTRUCTIONS 8. Go to the other end and tension the cable by holding the cable tightly with cable gripping pliers while turning the receiver with an Allen hex wrench. Be careful to protect the cable from damage while tensioning. 9. Tension in sequence beginning with the center cable and moving back and forth toward the top and bottom. As each cable is tensioned, give a sharp pull downward midspan to help set the locking wedges in the pull-lock fitting. Then re-tension as necessary in the same sequence. 10. Cut the cable flush with the hole in the back of the fitting using a cut-off wheel. Then press cap onto fitting.
NOTE: Same fitting is used for level and stair applications. NOTE: If using Flex Fittings with a composite sleeve or wrapped post, alternative screws will need to be purchased that will provide 2-1/2" of embedment to the structural post. FOR WOOD, WOOD WRAPPED, AND COMPOSITE SLEEVE POSTS FlexFX INSTALLATION INSTRUCTIONS TOOLS REQUIRED FOR INSTALLATION • Tape measure • Cordless drill • T25 screw bit • RailFX Universal Drilling Template (4900912)* • RailFX Flex Cable Install Kit (4903053FLX)* • Cable cutters (4903068)* *sold separately TO MEET CODE REQUIREMENTS, CABLES MUST NOT SPAN MORE THAN 4' WITHOUT A POST OR CABLE SUPPORT BRACE. NON-TENSIONER WITH WOOD POST TENSIONER WITH WOOD POST TENSIONER WITH COMPOSITE POST 41 |
STEP 1: Update Step 1 to read: Drill posts for cable and fittings using the RailFX Universal Post Drilling Template. For 36" rail heights, cut 8" off one end of drilling template to fit the posts. If not using the drilling template, use a tape measure and mark 3-1/8" from bottom of top rail to first hole. (Note: cable spacing is 3-1/8"). END POSTS: • Using RFX Universal Drilling Template, clamp the template to the inside face of each end post, aligning the top side of the template to the underside of the top rail and center the template to the post. • Using a 1/8" drill bit, drill approximately 1/4" into the post. This will mark where each fitting will be attached to the post with the supplied 2-1/2" screw. • Using a T25 bit, attach Flex Mounting Cups (FF-MC-W) to the post using the supplied 2-1/2" Stainless Steel Screw or longer screws (sold separately) for sleeved posts. It may be necessary to pre-drill before the mounting bases are installed if screws are being installed into a hard wood. 42 |
• Attach all non-tensioning and tensioning hardware to the mounting bases. (Note: Make sure all tensioning fittings are adjusted to the same location - ensuring enough thread turns remain for final tensioning of the cables). ASSEMBLING ASSEMBLED STEP 2: DRILL INTERMEDIATE POSTS • Each intermediate post will need to be drilled all the way through so the cable can pass through to the next intermediate post or end post. Center and clamp Universal Post Drilling Template to one side of the intermediate post. Mark hole locations with pen or marker for each hole in the template. Then move the template to the other side of the post and repeat this process for all intermediate posts. • Remove template and, using a 7/32" drill bit, drill halfway through posts for all holes on each side of post. NOTE: If cable is transitioning out of the post at an angle, use RFX Post Protector Tubes (4903061). Holes in post must be 1/4" diameter for installation of 3061. | 43
STEP 3: INSTALL AND TENSION CABLES • Using 100' or 500' bulk cable, lace cable through the intermediate post starting at the end the tensioning fittings are installed. Use Cable Lacing Needle included in the RailFX installation kit (3053FLX). • Push cable into the non-tensioning fitting by pushing cable into fitting while rotating cable in a clockwise direction. After insertion, stop rotating cable and push in. This will keep the cable from unraveling. 44|
• Go to the other end of the cable and pull cable tight and align cable with cut mark on the tensioning end fitting. Mark cable and cut with RFX cable cutters (3068). • Push cable into the Tensioning fitting by pushing cable into fitting while rotating cable in a clockwise direction. After insertion, stop rotating cable and push in. This will keep the cable from unraveling. Repeat this process for each run of cable. • Tension cable using the wrenches in the RFX installation kit. Tension all cables to specified tension of 225 lbs., beginning with the center cables, moving up and down toward the top and bottom. As you tension each cable, give it a sharp pull downward mid-span to help set the wedges, then re-tension as necessary in the same sequence. Be aware that the cable may move as much as 3/16" toward the tensioning terminal as the wedges seat. 45|
• Max Post Spacing- 5’ • Max Cable Run 40’ (2 Corners), 50’ (1 Corner), 60’ (Straight) • Add appropriate rail lengths • 452US- Add 0118, 0410, 0415 • 452UI- Add 0412, 0415 • 362FC (Inside Corner) - Add 0122, 0424 • 362FC (Outside Corner) - Add 0122, 0425 • 362FI- Add 0415 • 362FE (End of Run) - Add 0112, 0415 • Add 0417 (wood) or 0418 (concrete) for every post • Add 0910 (estimate 6 screws per post, sold 100 per pack) • Add 0911 Note: Runs over the allowed span must use a double post corner using the 0423 bracket to create two seperate shorter runs. Add 362FE (x2), 0122, 0423 Diagram Color Item # Black 452US Green 452UI Dark Green 362FC Gray 362FI Blue 362FE Teal 0424 Pink 0425 Red 0415 Orange 0423 Magenta 200 (Rail) Purple 250 (Rail) 0424 Detail 0425 Detail 46 | Basic 200/250 Fascia Mount Layout
0125 0113 • Max Post Spacing- 5’ • Max Cable Run 40’ (2 Corners), 50’ (1 Corner), 60’ (Straight) • Add appropriate rail lengths • 452US- Add 0118, 0410, 0414 • 452UI- Add 0412, 0414 • 362SC (Standard)- Add 0122 • 362SC (Top of Stair)- Add 0118, 0125, 0112 • 362SI (Top of Stair)- Add 0118, 0113 • 362SE- Add 0112 • Add 0120 for every post • Add 0417 (wood) or 0418 (concrete) for every post • Add 0910 (estimate 6 screws per post, sold 100 per pack) • Add 0911 Diagram Color Item # Light Blue 452US Yellow 452UI Red 362SC Green 362SI Gray 362SE Pink (Rail) 200 Blue (Rail) 250 47 | Basic 200/250 Surface Mount Layout
LEAN ON US® SCAN FOR RAILFX® INSTALLATION RESOURCES 800-745-5931 www.crownheritage.com
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