Melton Classics, INC.
B	BALUSTRADE/RAILING SYSTEM INSTALLATION INSTRUCTIONS

L

A	*Melton Classics, Inc. is a manufacturer of quality molded urethane. Our product is designed to withstand moisture, insects, and the outside elements. Our millwork
has a painted ﬁnish that is chemically bonded during the molding process. This
U	base coat will not peel or crack. An additional primer is applied prior to shipping.
S	We do recommend top-coat painting mouldings with an exterior paint.
T
•	Most states use the 4” BALL to meet
R	building code regulations. This rule is that
A	a 4" ball cannot pass through the widest
D	opening between balusters.
E

•	Structural integrity is the responsibility of the installer.
•	Custom items cannot be returned or cancelled once the production
has already begun.
•		Proper safety procedures are to be used when installing, sanding, or sawing our product, such as  wearing safety glasses and a dust mask. Urethane dust can be irritating and should not be inhaled.
•	Using Melton Classics, Inc. products does not contribute
to depleting our valuable forests.
•	Melton Classics, Inc. products should be stored in the
temperature conditions in which they will be installed.
•	Melton Classics, Inc. warrants all of its’ products against
defects in materials and workmanship for a period of 1 year from the date of purchase, when used and installed under recommended conditions.
•		Melton Classics, Inc. offers balusters with extensions on top and bottom for stair application.

Melton Classics • P.O. Box 465020 • Lawrenceville, Georgia 30042 • Telephone 800-963-3060
Fax: 770-962-6988 • www.meltonclassics.com • info@meltonclassics.com
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Newel Post Installation Kit
(Order 1 kit per Newel Post)	B

Kit Number*	Newel Posts	
MNPK 300-4	Fits all 4" newel posts	
MNPK 300-6	Fits all 5 1/2" newel posts	
MNPK 300-8	Fits all 8" newel posts	
MNPK 300-9	Fits all 9" newel posts	
MNPK 300-10	Fits all 10" newel posts	
MNPK 300-12	Fits all 12" newel posts	

Wood Kit	A
1. One ﬂoor ﬂange	L

U

2. Four 3/8" x 2" lag bolts
3. One 1/2" x 48" threaded rod
4. One “C" channel	S

T

5. One 1/2" ﬂat washer
6. One 1/2" lock washer
7. One 1/2" Nut	R
A

*Note: Newel Kits are available for either wood or concrete application. To
specify please add -W for wood or -C for concrete to the end of the kit number.
Ex. (MNPK 300-4-W or  MNPK 302-8-C)

MADE IN THE
USA

Concrete Kit
1. One ﬂoor ﬂange	D
2. Four 3/8" x 2  1/4" concrete wedge bolts	E
3. One 1/2" x 48" threaded rod
4. One “C" channel
5. O ne 1/2" ﬂat washer
6. One 1/2" lock washer
7. One 1/2" nut

Railing Installation Kit
(Order 1 kit per Top & Bottom Rail Section.)

Kit Number	Fits These Rails	
MRK 180	MTR 180, MTR 232-MBR 233, MTR 212-MBR 213	
MRK 200	MTR 182-MBR 183
MTR 200-MBR 201, MTR 202-MBR 203
MTR 210-MBR 211
MTR 760-MBR 761	
MRK 204	MTR 204-MBR 205, MTR 218, MTR 220	
MRK 206	MTR 206-MBR 207, MTR 214-MBR 215	
MRK 208	MTR 208-MBR 209, MTR 216	

Railing Kit

1. Two pre-drilled aluminum angle brackets. (Top Rail)
2. Two pre-drilled aluminum angle brackets w/ 5/16" tapped hole. (Bottom Rail)
3. Eight #14 x 2" self tapping screws.
4. Four 1/4" x 2" Panhead bolts.
4. Two 5/16" x 1  1/2" hex head bolts.

STAIR RAIL KITS Simply add an MRK-(S) MRKS 200
*Note: Must provide rise & run.

Melton Classics • P.O. Box 465020 • Lawrenceville, Georgia 30042 • Telephone 800-963-3060
Fax: 770-962-6988 • www.meltonclassics.com • info@meltonclassics.com
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*IMPORTANT* STEP 1
B	Mark the layout line and center points of each porch post and newel post prior to installation.
A	This is very important to ensure the accurate length for installing the top and bottom rails. Use
L	12’ as the maximum railing length.
U
S	STEP 2

T

WOOD DECKING INSTALLATION
1. Install blocking under where each newel’s ﬂoor ﬂange will be located.
R	2. Locate and center each ﬂoor ﬂange and secure using 3/8" lag bolts.

A

3. Thread the 1/2" x 48" rod into the welded nut on the ﬂoor ﬂange and
tighten using vise grips.
D
E	CONCRETE INSTALLATION
1. Mark anchor hole in ﬂoor ﬂange. Drill a 3/8" hole 1 1/4" deep into the cured concrete.
2. Insert anchor and using a punch, set the anchor pin.

STEP 3
1. Measure and combine the heights of the bottom rail and baluster (Distance X). This is the distance between the bottom of the angle brackets used to fasten railings to posts.
2. Mark the location and height of the bottom rail from the concrete or wood surface (Distance B).
3. Using the measurement of the rail and baluster (Distance X), locate the bottom of the top bracket.
4. Mark the top and bottom bracket on the newel post.
5. Mortise the newel post so that the face of the angle brackets are inset
and are ﬂush with the surface of the newel post.
6. Drill holes and secure angle brackets with #14 x 2 self tapping screws.

STEP 4
1. Rout the top of the newel post to accept the C-channel.
2. If trim collars are being used, slide them on the bottom
before placing the newel post over the ﬂoor ﬂange.
3. Put the C-channel in place and secure loosely with the nut and lock washer.

Melton Classics • P.O. Box 465020 • Lawrenceville, Georgia 30042 • Telephone 800-963-3060
Fax: 770-962-6988 • www.meltonclassics.com • info@meltonclassics.com
30

BALUSTRADE SYSTEM Installation Instructions

1. Determine your rail length.
2. Cut top and bottom rail to proper size.

STEP 5

B

3. Mortise the bottom of each rail to accept the 2 1/2" aluminum angle.	A
4. Drill a single 5/16" hole in the bottom rail that corresponds with
the single 5/16" threaded hole on the bottom 2 1/2" x 2 1/2"	L
aluminum angle.	U
5. Mark a center line on rails. Mark the position of each baluster then
drill a hole to accept the PVC pipe that extends out either end of the baluster. Standard	S
hole saws work well for drilling these holes.	T
6. Apply a bead of urethane adhesive to the bottom of each baluster and place the balusters
in the holes of the bottom rail. Apply a bead of urethane adhesive to the tops of each	R
baluster and set the top rail on the balusters. Clamp together using strap clamps,	A
making sure baluster blocks are square to the bottom and
top rail. A straight strip of plywood wedged between the	D
baluster blocks and strap clamps helps to align baluster	E
blocks straight and parallel to the top and bottom rail.
7. Allow the adhesive to set for 12 hours.

STEP 6
1. Remove the strap clamps from completed railing section.
2. Apply a small bead of urethane adhesive to the aluminum angles that are fastened to the newel posts, and to the ends of each top and bottom rail.
3. Leave the newel posts loose so you can slide the glued up rail section between them without smearing glue on exposed parts of the newel post.
4. Fit the mortises on the undersides of the rail onto the 2 1/2" x 2 1/2" aluminum angle that is
mounted to the newel post.
5. Predrill 1/8" holes through the holes in the top aluminum plates into the PVC pipe. Install 2
#14 x 2" pan head self tapping screws.
6. Thread the 5/16" x 1 1/4" bolt through the bottom plate and into the 5/16" hole you drilled in the underside of the bottom rail. (*Note: This 5/16" threaded bolt does not provide downforce. It is intended to keep the rail from moving laterally. Typical installations
do not have enough room between the decking and the underside of the bottom rail for the use of screws.)
7. After securing rail section to newel posts tighten up the nut on the newel post, securing it to the deck.
8. Apply a small bead of urethane adhesive to the top of the newel post and glue the newel cap in place. Small brad nails will keep the cap aligned until the glue sets.

Melton Classics • P.O. Box 465020 • Lawrenceville, Georgia 30042 • Telephone 800-963-3060
Fax: 770-962-6988 • www.meltonclassics.com • info@meltonclassics.com
31

STEP 7
1. After the glue dries, clean off excess with a sharp putty knife. Caulk any cracks with a good
B	quality latex paintable caulk.

A

2. Melton Classics, Inc. recommends applying a ﬁnish coat of latex paint to your
railing system..
L
U	C-Channel

S                                                  Top Rail Bracket
T
R A D

E

Mortise Rail Ends
& Newel Post

Urethane Adhesive

Bottom Rail Bracket

5/16” Bolt

Floor Flange

H-bracket

Pre-drilled Holes Secure rail with screws.

OVER THE NEWEL INSTALLATION

MADE IN THE
USA

Melton Classics • P.O. Box 465020 • Lawrenceville, Georgia 30042 • Telephone 800-963-3060
Fax: 770-962-6988 • www.meltonclassics.com • info@meltonclassics.com
32

Over the Newel Post Installation Kit
(Order 1 kit per Newel Post)	B

Kit Number*	Newel Posts	Fits	
MNPK 304-8	In-Line Kit	8" Newel	
MCNPK 304-8	Corner Kit	8" Newel	
MNPK 304-12	In-Line Kit	12" Newel	
MCNPK 304-12	Corner Kit	12" newel	

A

Wood Kit
1. One ﬂoor ﬂange

L

2. Four 3/8" x 2" lag bolts
3. One 1/2" x 48" threaded rod
4. One “C" channel	U
5. One 1/2" ﬂat washer
6. One 1/2" lock washer	S
7. One 1/2" Nut

8, One Top Rail H-Bracket

Concrete Kit
1. One ﬂoor ﬂange
2. Four  3/8" x 2-1/4" concrete wedge bolts
3. One 1/2" x 48" threaded rod
4. One “C" channel
5. O ne 1/2" ﬂat washer
6. One 1/2" lock washer
7. One 1/2" nut
8. One Top Rail H-Bracket

*Note: Specify -W for wood application or -C	T

R

for concrete application
Ex. (MNPK 304-8-W or  MNPK 304-8-C)
The only change for the OVER THE NEWEL	A
INSTALLATION is the H-bracket is through bolted	D

E

on top of the C-Channel of the Newel Kit. This also
eliminates the need for standard top rail brackets. The top rail is then secured with screws through the pre- drilled holed in the H-Bracket.

Over the Newel Railing Installation Kit
(Order 1 kit per Rail Section)

Kit Number	Fits These Rails	
MRK 206-B	MTR 206, MBR 207, MTR 214, MBR 215	
MRK 208-B	MTR 208, MBR 209, MTR 216	

* STAIR APPLICATION  - Standard Stair Rail Kit.
& Newel Kit. Over the Newel Kits are not made to work on stairs.

* Comes with Bottom Brackets only.

Over the Newel Railing Kit
1. Two pre-drilled aluminum angle brackets
w/ 5/16" tapped hole (Bottom Rail)
2. Eight #14 x 2" self tapping screws
3. Four 1/4" x 2" Panhead bolts
4. Two 5/16" x 1  1/2" hex head bolts

RAIL KITS
Part No. MRK 208 ; MRK 216

STAIR RAIL KITS
Part No. MRKS 208 / MRKS 216

**Customer must specify rise and run of stairs
1 KIT PER TOP & BOTTOM RAIL SECTION

Melton Classics • P.O. Box 465020 • Lawrenceville, Georgia 30042 • Telephone 800-963-3060
Fax: 770-962-6988 • www.meltonclassics.com • info@meltonclassics.com
33

BALUSTRADE SYSTEMS

Order Calculation & Information Sheet
B	Calucate Number of Balusters
A	Divide the rail length between your newel posts by
L	the (S) dimension under each baluster in the catalogue.
S = Spacing on Center
U
S	Stair Rail Kits - Provide Rise & Run of Steps
T
R	Rise  	”
A	Run
D	Run  	”	S
E
Radius Rails Information
Provide Radius, or Width & Projection of the Porch or from Springline.

RADIUS  	

or  (Width  	" ,   Projection  	“ )

Melton Classics • P.O. Box 465020 • Lawrenceville, Georgia 30042 • Telephone 800-963-3060
Fax: 770-962-6988 • www.meltonclassics.com • info@meltonclassics.com
34