3 Simple Methods For Attaching Bar Foot Rail Endcaps

When it comes to installing bar foot rails, one common question we often receive is how to properly secure the end cap inside the bar foot rail tubing. Many customers are surprised to find that the internally fitting bar rail end caps seem to fit loosely when assembling bar foot rail.

This looseness is actually intentional and by design. Bar rail end caps are made to fit loosely to accommodate slight variations in tubing size that may occur during the manufacturing process. This also allows the caps to fit multiple tubing diameters, ensuring they work across different setups without needing custom sizing.

So, when you reach the stage of assembling your bar foot rail, and it's time to insert the end caps, you might notice that they don’t fit as snugly as you expected. Thankfully, securing the end caps is a simple process, and we recommend three easy methods to achieve a proper fit.

Securing with a Set Screw

One way to secure the end cap is by drilling a small hole through the bar rail and using a set screw to hold the fitting in place. While this method works effectively, it does require precision with drilling and some extra tools, which might not be ideal for everyone. If you're comfortable with a drill and don't mind adding a small screw to the bar rail, this can offer a more permanent solution.

Using Masking Tape

We recommend using masking tape to secure the end cap for a more user-friendly approach. This method is quick, easy, and doesn’t involve drilling or the risk of scratching your bar rail’s finish.

Simply wrap the stem of the end cap with several layers of masking tape. The number of layers depends on how much additional snugness you need.

Once wrapped, slide the end cap into the bar rail. The tape will create a snug fit, holding the cap securely in place without any need for tools or screws.

The masking tape method is particularly useful if you ever need to remove the end cap in the future. With no screws to remove or risk of damaging your rail, this method offers both convenience and protection for the finish of your bar foot rail.

Using JB Weld SuperWeld

For those looking for a stronger, more permanent hold, you can use JB Weld SuperWeld or a similar adhesive to secure the end cap inside the tubing. This industrial-strength super glue creates a powerful bond that will keep your end caps firmly in place.

Apply a small amount of JB Weld SuperWeld to the stem of the end cap. Carefully slide the end cap into the bar rail, ensuring it is properly aligned. Hold the end cap in place for a moment to allow the adhesive to bond.

This method ensures a long-lasting and durable hold, making it an excellent choice for high-traffic environments or areas where the bar rail will be subjected to frequent use. However, keep in mind that this is a permanent solution, and removing the end cap later may be difficult without damaging the tubing or cap.

While each method offers a secure way to fit bar rail end caps, the best option depends on the project’s specific needs. For an easy and reversible solution, the masking tape method is ideal. For a more permanent hold, you can opt for either the set screw method or the use of JB Weld SuperWeld. Whichever method you choose, you'll ensure a professional and secure fit for bar foot rail end caps.