u/JustAGuy10024

Hey folks, looking for some technical advice on an in-place modification I need to get done on a stainless steel staircase.

We are removing an old wire mesh infill and converting it to a 10-cable horizontal system. The catch: the staircase cannot be dismantled. All the work needs to be done in the field. (The place is a gut-renovation construction zone right now, so making a mess or throwing chips is perfectly fine).

A previous contractor scoped this out before COVID but retired before the job happened. I'm trying to figure out the best way to execute his plan or find a smarter alternative before I start bringing in local fabricators.

The Challenges:

1. Adapting the existing tabs:

The current mesh is held to the end posts by welded tabs. The retired contractor suggested keeping these welded tabs and using some sort of adapter to attach the new horizontal cable tensioners directly to them (rather than cutting the tabs off and trying to grind/re-grain the post flush). Have any of you tackled something similar? What kind of hardware or adapter would mate well to a flat welded tab to hold a cable tensioner securely?

2. Drilling & tapping stainless in the field:

If we end up having to drill and tap the main posts to receive new cable end terminations, what is your recommended setup for doing this by hand/on-site without work-hardening the hell out of the stainless? Specific bits, tapping fluids, or portable fixturing (like a mag drill base for non-magnetic stainless?) you'd recommend?

3. The intermediate posts:

The cables need to be supported mid-span. The previous guy assumed we'd just drill clearance holes straight through the intermediate posts. If we go that route, what's the best way to jig/fixture it so we get 10 perfectly aligned holes down the line? Alternatively, are there any clever bolt-on/clamp-on standoffs we could use to avoid drilling through the intermediate posts entirely?

I’ve attached a few photos so you can see what I'm working with: a wide shot of the stairs, a close-up of the existing welded tabs, and the previous contractor's design concept.

Any tooling recommendations or hardware ideas are hugely appreciated!

I’m looking for some input on the best approach to modify an existing stainless steel staircase in my apartment. We are currently doing a major renovation to combine adjacent units, so the space is already set up for heavy, messy work—dust and noise aren't a concern right now. However, the staircase cannot be dismantled; all work needs to be done in place.

Currently, the stairs and upper landing have a stainless steel wire mesh infill that is held by welded tabs. I want to remove the netting and replace it with a 10-cable horizontal system.

A previous contractor actually scoped this out before COVID, but he retired shortly after, so the job never got done. His proposal was to keep the existing welded tabs, use an adapter on them, and attach the horizontal cables directly to those same tabs.

My main questions for the group:

1. Hardware: What kind of adapters or hardware would work best to transition from the existing welded tabs to a clean, tensioned horizontal cable setup?
2. Intermediate Posts: The retired contractor assumed we would need to drill clearance holes in the intermediate posts for the cables to pass through. I'm open to that, but are there other, potentially cleaner ways to handle the cable routing on those middle posts?
3. In-place execution: Since this all has to be fabricated and tensioned in place, are there any specific tools, techniques, or pitfalls to watch out for?

I’ve attached photos of the current full staircase, close-ups of the existing tabs/hardware, and the generic proposal/design plan from the retired contractor for reference.

Thanks in advance for any ideas!

I’m looking for some input on the best approach to modify an existing stainless steel staircase in my apartment. We are currently doing a major renovation to combine adjacent units, so the space is already set up for heavy, messy work—dust and noise aren't a concern right now. However, the staircase cannot be dismantled; all work needs to be done in place.

Currently, the stairs and upper landing have a stainless steel wire mesh infill that is held by welded tabs. I want to remove the netting and replace it with a 10-cable horizontal system.

A previous contractor actually scoped this out before COVID, but he retired shortly after, so the job never got done. His proposal was to keep the existing welded tabs, use an adapter on them, and attach the horizontal cables directly to those same tabs.

My main questions for the group:

1. Hardware: What kind of adapters or hardware would work best to transition from the existing welded tabs to a clean, tensioned horizontal cable setup?
2. Intermediate Posts: The retired contractor assumed we would need to drill clearance holes in the intermediate posts for the cables to pass through. I'm open to that, but are there other, potentially cleaner ways to handle the cable routing on those middle posts?
3. In-place execution: Since this all has to be fabricated and tensioned in place, are there any specific tools, techniques, or pitfalls to watch out for?

I’ve attached photos of the current full staircase, close-ups of the existing tabs/hardware, and the generic proposal/design plan from the retired contractor for reference.

Thanks in advance for any ideas!