Railing ideas?

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Customer wants 3  2"x4" rectangular tubes running horizontal between Wooden posts that are in place and not plumb.  Some are out as much as  1/2" from top to bottom.  11 sections total.  My thought was to use flat stock running vertical to lag into wood posts and use a "sleeve" or pocket for the 2x4 to slide into on both ends so you won't see any gaps etc..  My problem is that I can't find anything stock that slides over 2x4 I could make them out of flat weld, and grind but the thought of 66 of them makes me sick.  Any thoughts?  Travis
Reply:Could you use a router on the wood to make a bit of a pocket, that would allow you cut all the metal in a section the same size?Just my  opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com
Reply:would you have to over drill it to slide the metal in far enough to get the other side in?  The posts are holding up a very big deck can't remove them.  How would you retain them in the holes?  Thanks for the input.  TB
Reply:DichdocGot couple Ideas for you.One idea would be to build each section on the ground and attach them with a couple of temporary (break away)  bars.  Then set them into position and mark the pitch at each end then cut each custom to the opening.Another idea would be to cut angle. Bolt the angle to the tubing.  Drill the hole in the tubing larger than bolt, then lag bolt angle into the wood.  The large hole in the angle will allow some adjustment for the out of plumb wood.  I don't know what look you are trying to acheive.  Though if there is not enough room for the flange out on the wood then you could customize a bracket to go around the posts.  Wroughtnharv did a great post about "back bending". Check it out if you decide to form your own bracket.My only concern about using a full sleeve would be in the pitch is off too much then the tubing will not slide in at each end.  You could make your own sleeve with flat bar.  Do three sides only.You could even do decorative bolts, don't know what look you are going for.  It is times like these where I think about making things look they belong to compensate for the situation. I like the problem solving stuff, though  sometimes makes me wish I bid more.  Depending on the look, I could see myself removing and installing that job up to three times-especially since it is wood.  Also, you could make a jig for each sections and build each permanent section from that.  You could also take measurement of each section and build from the measurements.
Reply:If it were me I would just go ahead and measure each one to fit and weld tabs on ends of tubing . No sleeves. Ive made sleeves before but for sq tubing where you can use the next size larger and it its easier. But in your case with 2x4 I believe it would be quicker to make the measurements individually and cut to fit.BTS Welding
Reply:I was thinking of using 3/16" flat about 36" long and welding my three pieces to that but if one post is more out of plumb then the other I don't think I could get it "close enough".  I offered to chain saw the posts of flush and make steel ones but that wasn't the look he wanted!  This makes my head hurt.