System Equine Standard Stall Series Instruction manual

Standard Stall Instructions 2011 - Page 2
Outside Wall of Building
Door Post
Side Wall
DFig. A
C
A
B
Side Wall
Corner PostCorner Post
Stall Door
BEFORE YOU START
NOTE: All measurements are based on finished wood sizes. Example 2” x 6” finished size is 1 1/2” x 5 1/2”
Questions to Be Answered…
Careful consideration when designing your barn layout will save you time, money and frustration.
Do you want the horses to see one another?
Solid partition walls
Grilled partition walls
Privacy partition walls
Do you want to have the horses look out the front of the
stalls?
Flip down V- doors
Swing out feed doors
Shutter doors
Swing Down doors
Do you want to be able to feed from outside the stall?
Swing out feed doors
Feed Opening
What type of latch do you like?
Slide latch
Top latch catch
Horseshoe Latch
What type of wood are you using?
1 1/2" width is the standard thickness of the
U-Channel.
Are you concerned with good ventilation?
Grilled Front Walls
Grilled side walls
Full Grill doors
SY S T E M TI P
Standard Stall Sizes are 10’x10’, 12’x12’, 10’x12’ Make sure to plan for additions to your stable ahead
of time. System Standard Stalls feature options such as removable walls, feed doors, V-Doors & more.
ANY SIZE STALL CAN BE BUILT USING THE SYSTEM STALL SYSTEM
1. Corner posts can be set 10' or 12' (or any other spacing as
desired) on center to fit building design or special needs. The
Grill length (See C in fig A) of a standard 10’ stall front is 65” and
91” for a 12’ stall front. (See Fig. A). However, grill sections can
be combined to create any size of stall front you desire.
2. The inside distance between the door posts (See B in fig A) must
be 48". Posts used for the installation may be 6X6, 4x4, or 4X6.
If top of posts are not going to be anchored then a sufficient
amount of post should be placed deep enough in the footing to
provide adequate holding power. (We recommend a 3’ depth)
3. Install the corner posts first followed by the door posts. Make
sure all posts are plumb, true and level.
SY S T E M TI P
Keep in mind the finished size for 2” x 6” dressed lumber is 1 1/2” x 5 1/2”. If choosing tongue & groove as your
filler wood take in to account the loss of height due to the tongue & grooves. We recommend you use pressure
treated wood for the bottom two boards of your stall system.
NOTE: Wall sections that span over 12’ long will require a 4” x 4” center support post.
SECTION 10 FT. STALL 12 FT. STALL 14 FT. STALL
Front walls
(for header channel)
Grill Partitions
Solid Partitions
Posts* 4X4
4X6
6X6
10 - 2” X 6” X 10’
1 - 2” X 10” X 10’
9 - 2” X 6” X 10’
1 - 2” X 10” X 10’
18 - 2” X 6” X 10’
3 Needed per stall system except when stalls are added next to each other.
*See Fig. A above.
10 - 2” X 6” X 12’
1 - 2” X 10” X 12’
9 - 2” X 6” X 12’
1 - 2” X 10” X 12’
18 - 2” X 6” X 12’
10 - 2” X 6” X 14’
1 - 2” X 10” X 14’
9 - 2” X 6” X 14’
1 - 2” X 10” X 14’
18 - 2” X 6” X 14’
WOOD SPECS FOR SYSTEM STALL SYSTEMS

Standard Stall Instructions 2011 - Page 3
STEPS TO EASY INSTALLATION...
POST INSTALLATION
SY S T E M TI P
When you auger posts, all posts should be installed with the top at least 8’ above the ground. If the
posts are not properly secured at the top, they must be buried to a depth of at least 3’ to provide
adequate stability.
STEP 1
Refer to Fig. A page 2 to determine post locations for the size of stall
that has been selected.
STEP 2
Install the corner posts first, being careful to stay within the distances
A and D as given in the chart.
STEP 3
Install the door post to distance B to a tolerance of + or - 1/4”.
NOTE: Make sure all posts are checked for level on all sides.
STEP 4
Dimension C should be treated as the variable dimension if a problem
with post location should arise. In this event, it may be necessary to
cut some of the grill components.
NOTE: Post can be installed in several ways. The most common is to auger into the ground and using post anchoring plates.
STALL ARRANGEMENTS USING 3 1/2”X 3 1/2” POSTS
10’ STALL FRONT
A = 116.5”
B = 48”
C = 65”
D = 120”
12’ STALL FRONT
A = 142.5”
B = 48”
C = 91”
D = 144”
SY S T E M TI P
CHECKING FOR SQUARE: Measure from one corner diagonally to the opposite corner (top left to bottom
right) and repeat for the other corner, measurements should be the same. If they are not, tap the corner of
the longest measurement until you have two equal measurements. This will ensure your work is square.
SY S T E M TI P
With all posts in place it is time
to order your lumber and unpack
the stall components. Review the
assembly drawing to familiarize
yourself with the names and locations of the parts. Try not
to mix boxes.
TO AVOID MISTAKES PERFORM EACH STEP IN THE
SEQUENCE SHOWN.
FRONT WALL ASSEMBLY
STEP 1 (See Fig. 1B, on page 5)
1a. Install the 46" U-channels on the corner and door posts with the
screws provided. (channels under grillwork)
1b. U-channels should be set back 1/2" from the front face of the posts.
1c. The U-channels should be set + or - 1/2" above the floor.
STEP 2
Cut all necessary lumber to a length 1/4" to 3/8" less than the distance
measured between the inside faces of the U-channel.
STEP 3
Installing the lumber in the U-channels.
3a. Slide the first board down to the bottom of the U-channel ensuring
that it is level. (pressure treated lumber can be used for the bottom
of the stall wall)
3b. Firmly secure the bottom board with the screws provided before
installing the remaining boards.
STEP 4
Install all remaining boards ensuring that they come to a height of 1 1/8"
above the top of the U-channels. It may be required to rip cut a board to
achieve the correct height.
STEP 5
Install the rubber grommets as shown in Detail D on page 5 for both the
bottom and top grill channels.
STEP 6
Install the bottom grill channel flush with the top of the U-channels, secure
the channel with the screws provided.
STEP 7
At a height 36 3/8" install two 7" header U-channels above the top of the
46” U-channel.
STEP 8
Place the 2” x 10” header board in the 7” U-channels allowing it to extend
1/2” bellow the 7” U-channels. Use a screw at each end to hold the header
board in place for now. Put the top grill channel in position on the bottom
of the header board again hold in place with screws.
STEP 9
Insert the grill bars starting at one end. Place the grill bars in the top grill
channel then lower into the bottom grill channel, repeat until all bars are
in place. When all bars are in place remove the screws used to hold the
header board and top grill channel. Push or pull down on the header board
until it sits evenly on the top of the grill bars. Now secure the header and
top grill channel in place with the screws provided.
STEP 10
THE FOLLOWING IS FOR 12’ FRONTS OR LARGER ONLY. Install the
one wall brace placing it on the inside of the wall.
NOTE:
• 12’ Front walls come with one 46” wall brace.
• Grilled partition walls come with two 46” wall braces, 1 for each
side.
• Solid partition walls come with two 94” wall braces one for each
side.
SY S T E M TI P
There are two 7” header U-Channels provided with each stall door to install an optional 2”x10” lumber
header in the door opening for added strength. Installation instructions for Optional Header are on page 8
of this manual.

¼” x 2-1/2” Lag,
Spring & Plastic Washer

Standard Stall Instructions 2011 - Page 5
FRONT WALL ASSEMBLY
Detail E
Door
Catch
Detail F
Door header & 7" header channel optional Minimum 2"x10" Lumber
Door Track (Round) Door Track (Round)
One 46" Wall Braces place on inside
of wall supplied with 12' Stall Front only.
Stay
Roller
Post Bumper
31 /2" 31 /2" 31 /2"
Wall Capping (optional)
7" Header
U Channel
U-Channel
Bottom Grill
Channel
Top Grill
Channel
Rubber
Grommets
Wall bumper
Detail D
Rubber Grommet
Installation
Note:
U-Channel 1/2"
above finished floor.
93"
from the top
part of the
bracket to the
floor
36 3/8"
48" Door Opening 10' Stall Front = 65" grill
12' Stall Front = 91" grill
Top door track facemount brackets Offset track bracket
Grill Rods
3/8" X 2 1/2" Lag bolts 5/16" X 1 1/2" Lag bolts
Detail B
Door Latch
Assembly
Detail A
Door Handle
Assembly
Detail C
Trolley
Assembly
Door side
U-channel
Door bottom
channel
Door side
U-channel
Door bottom
grill channel
Door top
grill channel
Door insert
See pg. 7
Fig. 2 for detail
Door top
channel
Continuous top bracing used on free standing stall or cathedral ceilings when posts are not secured to ceilings or rafters
5/16" X 1 1/2" Lag bolts 5/16" X 1 1/2" Screws
1 1/2"
Rod
Rubber
Grommet
Lumber
Grill
Channel
Grommets
sit on top
of wood
Detail D
Rubber Grommet Installation
NOTE: Use a soft faced mallet to tap grommets into place.
Horseshoe Latch Slide Latch
Fig. 1-B
NOTE: use a soft mallet to tap grommets
into place. Grommets are really hard to
remove if set into U-Channel properly.
Detail E
Facemount Bracket
Detail F
Offset Bracket
Optional Door Latches
Stay Roller Post Bumper Wall Bumper
Round Track
End Cover

Standard Stall Instructions 2011 - Page 6
SIDE WALL ASSEMBLY (GRILLED & SOLID PARTITIONS)
NOTE:
The U-channel required for a solid wall partition is 94 1/2" long
The U-channel required for a grilled wall partition is 46" long
STEP 1
First, select the U-channel for the type of wall partition to be installed. Install
one U-channel in the center on either the corner or outside wall at + or - 1”
above the stall floor.
STEP 2
Cut all the necessary lumber to a length 1/4" to 3/8" less than the distance
measured between the inside faces of the U-channels.
STEP 3
Installing the lumber in the U-channels
3a. Slide the first board down the U-channels all the way to the floor and
ensure that it is level.
3b. Firmly secure with the screws provided.
NOTE: For solid partition walls
- Install all remaining boards and secure with the screws provided
- Install the two 94” wall braces (one each side) with the screws provided.
STEP 4 NOTE: Remaining steps are for grill partition walls.
Install all remaining boards ensuring that they come to a height of 1 1/8"
above the top of the U-channels. It may be required to rip cut a board to
achieve the correct height.
STEP 5
Install the rubber grommets as shown in Detail D on page 5 for both the
bottom grill channel and the corresponding top grill channel.
NOTE:
Use a soft face mallet or your fingers to install the rubber grommets into
place.
STEP 6
Install the bottom grill channel flush with the top of the U-Channels.
NOTE:
- For a 10' partition wall, two 6' and two 4' grill channel are utilized
- For a 12' partition wall, two 6' grill channels are utilized
- For a 14' partition wall, four 6' grill channels and two 21.5" channels are
utilized. NOTE: Wall sections that span over 12’ long will require a 4”
x 4” center support post.
- Install the 6' channel first by butting it flush with the face of the post. Install
the second channel for the appropriate distance. It may be necessary to
cut this component. Then attach channels with the screws provided.
STEP 7
At a height 36 3/8" install two 7" header U-channels above the top of the 46"
U-channel.
STEP 8
Place the 2” x 10” header board in the 7” U-channels allowing it to extend 1/2”
below the 7” U-channels. Use a screw at each end to hold the header board
in place for now. Put the top grill channel in position on the bottom of the
header board again hold in place with screws.
STEP 9
Insert the grill bars starting at one end. Place the grill bars in the top grill
channel then lower into the bottom grill channels, repeat until all bars are in
place. When all bars are in place, remove the screws used to hold the header
board and top grill channel. Push or pull down on the header board until it
seats evenly on the top of the grill bars. Now secure the header and top grill
channel in place with the screws provided.
STEP 10
Install the two wall braces, 46" for grilled walls or 94 1/2” for solid walls,
placing one on each side of the wall opposite each other and centred in the
partition.
FEED DOOR STYLES
Hinge
Point
Pull down
& open
Hinge
Point

Swing-Out Feed
Door Installation
1. First decide where you want the
swing-out feed door located.
2. Omit 7 bars from the grill section
(Stay at least one bar from either
end of the grill section)
3. The swing-out feed door comes
completely assembled and ready
for installation and is installed in
the same way as the grill bars.
Feed Opening
Installation
1. First decide where you want the feed
opening.
2. Cut two bars to the desired length, 22”
long bars will leave approximately a 12”
opening.
3. Slide feed opening over the two outer
bars of the opening. Let the feed opening
plate rest on the bottom grill channel.
Insert the two cut bars in the top grill
channel and slide the feed opening up
until it is tight with the two bars. Use the
self-drilling self-tapping screws to hold
the feed opening plate in place. Note:
Screw through feed opening plates into
the outer bars of the opening. Place
screw at all four corners as shown.
FLIP DOWN V-DOOR
FliDr
V-Door
Installation
The V-Door grill section is delivered pre-1.
assembled as one-piece
Follow the Stall Door Assembly steps as2.
outlined on page 7 with Step 3 omitted
V-Door not exactly as shown.

Standard Stall Instructions 2011 - Page 7
STALL DOOR ASSEMBLY
SY S T E M TI P
Only put screws on the front or outside of the stall door.
STEP 1
Cut 10 pieces of 2” x 6” lumber to a length of 50 1/2”.
STEP 2
Lay out door components as shown in Fig. 2, on a flat surface.
STEP 3
Insert the rubber grommets into the rod holes on the top and bottom
grill channels as shown in Detail D on page 5.
STEP 4
Door Header Assembly
Locate the door top channel and the door top grill channel and one
piece of 2” x 6” lumber cut to 50 1/2”. Place the lumber evenly
between the two channels and fasten securely in place. IMPORTANT:
Be sure the 3/4” punched holes for the trolley assembly line up.
STEP 5
Next take a drill with a 9/16” wood drill bit and drill straight through the
wood of the door header using the 3/4” punched holes as a guide. If
your drill bit is not long enough to drill all the way through, flip the
header over and drill from the other side.
STEP 6
To pre-assemble the of door side U-channels see Fig. 2 below. Install
door insert as shown inserting screws and tighten. Installation should
allow 5 1/2" from top of door insert to top of door side U-channel.
STEP 7
Lay out door components as shown in Fig. 2, on a flat
surface.
STEP 8
At this time turn to pages 4 & 8 for the installation of
the door trolley assembly and door latch. Completing
these steps at this time will make it much easier.
STEP 9
Position and secure in place the two pre-assembled
door side U-channels on either side of the door
header.
STEP 10
Place the bottom grill channel evenly on a piece of 2”
x 6” x 50 1/2” lumber. Then position it between the
door side U-channels tight to the inserts.
STEP 11
Now insert the grill bars starting at one side until all
bars are in position. Then secure the bottom grill
channel to the side U-channels with the screws.
STEP 12
Now fill up the rest of the door with the 2” x 6” x 50 1/2”
lumber.
STEP 13
Insert the door bottom channel over the last piece of
lumber and flush with the bottom of the door side
U-channels. Insert and tighten screws.
STEP 13
Make sure the door is square (see Tip on page 3) and
the door top & bottom channels butt against the door
side U-channels. Insert and tighten all the screws
down the length of both door side U-channels. Note:
Only put screws in front or outside face of door.
Screws placed on back or inside of door may interfere
with the door operation.
Door Bottom
Channel
Door side
U-channel
Door side
U-channel
Door Top
Grill Channel
Door
Insert Door Insert
Door Top
Channel
3/4" Holes punched for
door trolley assembly
5 1/2" 5 1/2"
Door
Bottom Grill
Channel
Rubber
Grommets
installed
Rubber Grommets installed into Grill Channel
Door Grill Bars
Fig. 2

Standard Stall Instructions 2011 - Page 8
FULL GRILLED STALL DOOR ASSEMBLY
SY S T E M TI P
Only put screws on the front or outside of the stall door.
STEP 1
Cut two pieces of dressed 2” x 6” and one piece of dressed 2” x 8” lumber to
a length of 50 1/2”.
STEP 2
Insert the rubber grommets into the rod holes of all for grill channels.
STEP 3
Lay out all door components as shown in Fig. 3, on a flat surface.
STEP 4
Door Header Assembly
Take door top channel and the door top grill channel (3 1/2” bar spacing) and
one piece of the dressed 2” x 6” board cut to 50 1/2” long. Place the channels
evenly on the board and fasten securely in place. Repeat these steps for the
bottom door channel and bottom door grill channel (2” bar spacing)
STEP 5
Center Grill Assembly:
Take the dressed 2” x 8”x 50 1/2” long board with the remaining top grill channel
(3 1/2” bar spacing) and the bottom grill channel (2” bar spacing) Place the
channels evenly on the board and fasten securely in place.
STEP 6
Door Side Insert Pre-assembly:
See Fig. 1 below. Install door insert as shown inserting screws and tighten.
Installation should allow 5 1/2” from top of door insert to top of door side
U-channel.
STEP 7
Lay out door components as shown in Fig. 3, on a flat surface.
STEP 8
Position and secure in place the two preassembled door side U-channels on
either side of the door header.
STEP 9
Place a center grill assembly in the approximate center of the door between the
door side U-channels.
STEP 10
Now insert the grill bars starting at one side until all bars are in position. Then
secure the center grill assembly to the side U-channels with the screws.
STEP 11
Now place the remaining bars in the bottom section of the door and slide the
bottom door grill assembly up in to the side U-channels be sure it is flush with
bottom of the side U-channels then secure in place.
STEP 12
Make sure the door is square and the door top & bottom
channels butt against the door side U-channels. Insert and
tighten all the screws down the length of both door side
U-channels. Note: Only put screws in front or outside face of
door. Screws placed on back or inside of door may interfere
with the door operation.
NOTE: ONLY A SLIDE LATCH CAN BE
USED WITH THIS DOOR.
Door Bottom
Channel
Door side
U-channel
Door side
U-channel
Door To p
Grill Channel
(3 1/2" bar spacing)
Door
Insert Door Insert
Door To p
Channel
2" x 6" x 50 1/2"
dressed size 1 1/2" x 5 1/2"
2" x 6" x 50 1/2"
dressed size 1 1/2" x 5 1/2"
2" x 8" x 50 1/2"
dressed size 1 1/2" x 7 1/2"
5 1/2"
5 1/2" 5 1/2"
5 1/2"
7 1/2"7 1/2"
Door
Insert Door
Insert
Door To p
Grill Channel
(3 1/2" bar spacing)
Door
bottom Grill
Channel
(2" bar spacing)
Door
bottom Grill
Channel
(2" bar spacing)
Rubber
Grommets
installed
Rubber
Grommets
installed
Center
Grill
Assembly
Rubber Grommets installed into Grill Channel
Bottom Grill
Assembly
Top Grill
Assembly
Rubber
Grommets
installed
Door Grill Bars (3 1/2" bar spacing)
Door Grill Bars (2" bar spacing)
View of fi nished door
Fig. 3

Standard Stall Instructions 2011 - Page 9
DOOR TROLLEY ASSEMBLY (see Detail C page 4)
STEP 1
Assemble Round Track Trolley as per enclosed instructions.
STEP 2
Drill through pre-punched hole in door top channel using a 9/16” drill bit.
STEP 3
Insert bolt and pre-assembled roller assembly through hole, use flat
washer and 2 hex nuts to secure in place that are included in your Round
Track Trolley Package.
TOP DOOR LATCH & HANDLE ASSEMBLY (see Detail B page 4)
STEP 1
Position the latch, spacer and latch holder in place on door, use the two
5/16” x 2 1/2” hex lag bolts to fasten them to the door.
STEP 2
Screw the 1/4” x 2 1/2” guide lag bolt with the spring and washer in posi-
tion leaving the latch approximately 1/2” to 5/8” of vertical movement.
STEP 3
Attach the lifting rod to the latch with the locking push cap.
STEP 4
Place the door in position and allow the lifting rod to hang level to deter-
mine the door handle location.
STEP 5
Lifting rod should extend approximately 1/2” to 5/8” below the top of the
inside of the door handle.
STEP 6
Fasten handle to door using the two 5/16” x 1 1/2” hex lag bolts.
DOOR INSTALLATION
STEP 1
Note: If using 3.5” posts, you will find that the facemount brackets will stick
out in between the posts. You may choose to hammer the overhanging
sections of the brackets back or simply cut off and file down any excess.
DOOR TRACK BRACKET INSTALLATION:
Three track mounting brackets are included in the hardware kit; 2 brackets
are top mounting facemount brackets with 5 bolt holes and 1 bracket is a
offset style bracket and has one top bolt and two wallmount bolt holes.
STEP 2
Our Round track has five notches in it across the top. To determine the
proper side to hang the track over the door opening, starting at the first
notch at the end, measure 52” to the third notch. This will allow you to
hang the facemount side brackets onto the posts,based on a 48” opening
for your door. Simply slide the notch of the facemount bracket into the hole
on the track and tap the bracket towards the outside with a hammer.
STEP 3
Measure 93” from the ground up each stall door post and mark a horizontal
line across each post. With help, lift your track so that the top of each
facemount bracket lines up with corresponding line. Attach the brackets
with 1 lag bolt into post. Reinforce with 2 screws into each hole on either
side of the lag. (2 people required for this step)
STEP 4
With help lift the door up and maneuver the trolleys into the door track.
Leave door at door opening supported by facemount brackets.
STEP 5
Now complete the door track assembly by inserting the remaining end cap
(DETAIL H – FIG 1B -PAGE 4) and offset bracket (DETAIL F – FIG 1B –
PAGE 4) on the end of the track.
IMPORTANT: Level the track before securing the offset bracket.
SHUTTER DOORS:
10’ Track with 1 Facemount Bracket & 3 Offset Track Brackets
STEP 6
With the door open and flush with the center door post install the wall
bumper to the header at the top back of the door. See FIG 1-B.
STEP 7
Secure the stay roller to the bottom center of the center door post. See
FIG 1-B.
STEP 8
Attach the post bumper to the bottom of the corner post approximately
1/2” off the floor. See FIG 1-B.
STEP 9
With the door in the closed position and approximately 3/8” away from
touching the post bumper. Install the door catch to the corner post
approximately 1/8” to 1/4” below the top to the door. See detail B page
4.
DOOR OPTIONAL HEADER ASSEMBLY
STEP 1
There are two 7" long U-channels provided with each stall door to install
an "optional" 2 “X 10” header board in the door opening behind the track
and directly in line with the lumber above the grill section.
STEP 2
Fasten the 7" U-channels 1" back from the front of the posts with the bot-
tom edge of the U-channel at a height of 83" and level from the finished
floor using the #12 X 1 1/4" screws provided.
*NOTE:
These U-channels are mounted at the same height as the ones used in
the grilled front or grilled partition.
STEP 3
Slide a piece of 2” X 10” lumber into the U-channels and leave 2" of lum-
ber protruding below the U-channels. Insert and tighten all screws on
both side of the U-channels.
*NOTE:
2 X 10 lumber length is 1/2" less than the stall door opening.
STEP 4
If optional wall capping is used, cut to desired length and slide firmly over
the bottom and top edge of the 2” X 10” lumber in the door opening and
secure with screws.