Installation Instructions
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In situations where a stock rail needs to be reduced in length, the following points must be observed.
The stairway must first be measured.
The measurement must be taken from the landing at the top of the staircase to the floor at the bottom, in one straight line, with the measure resting on the nose of each step. Make a note of this measurement. Add 8" (Overhang) to this measurement to give the total length of the rail required.
Example: Stairway = 148" + 8" = 156" rail length required.
Note: All measurements of the rail must be made on the underside of the rail (the side opposite the gear rack), as this is the side that rests on the stairway.
All cuts must be made at the very top of the rail.
Do not cut at the joint, as this is a precision cut to allow two pieces to join accurately.
Cutting the Rail
To cut the rail, first remove the uppermost section of gear rack. Note that the gear rack is 6" shorter than the rail itself. Now remove the upper charge point and its associated cables, which is affixed to the side of the rail. The top stopping limit ramp (screwed to the upper surface of the rail, near the top) must also be removed. Cut the rail to the required length, using a chop-saw, skill-saw or broad bladed hacksaw.
The upper section of gear rack must now be reinstalled. This too, must be shortened by the appropriate amount, so that it is 6" shorter than the aluminum rail section. For safety reasons, it is important that the difference in length between the gear rack and the rail section is maintained. The gear rack must be 6" shorter at the top, than the rail section.
The rail will now require drilling for the reinstallation of the charge point and the top stopping limit ramp. The charge point should be mounted so that its upper edge is 4½ below the cut. Drill 2 x 1/8" holes for the mounting screws (using the charge point molding as a template). Between these holes, drill a ½" hole, through which the charge point cable will pass. Ensure that the brown wire is attached to the uppermost strip on the charge point and the blue wire is attached to the lowermost strip. Also ensure that none of the metal components of the charge point or its wiring (aside from the fixing screws) are in contact with the rail itself, by insulating with electrical tape.
The rail is now ready for assembly and fixing to the staircase. The top stopping limit ramp should be reattached to the upper surface of the rail, after the stairlift carriage has been mounted on the rail.
[Instructions here]If you want to return to "Step 1: The Rail Assembly" of the installation instructions click here.