Think Fencing Zappa Rail User manual

Zappa Rail | Installation Guide 1
Rural Fencing
Zappa Rail.
Installation Guide

Zappa Rail | Installation Guide
2
Timberline x4 Rail – Red Gum

Zappa Rail | Installation Guide 3
Contents
Getting Started 4
Installation Tips 4.1
Electrifying 4.2
Tools Required 5
Instructions 6
Option One - Using Line Strainer 6
Option Two - Using Insulstrainer 12
Joining Zappa Rail using a Line Strainer 16
Joining Zappa Rail using a Joining Buckle 17

Zappa Rail | Installation Guide
4
Getting Started
Zappa Rail is an innovative fencing solution featuring two
high tensile wires built into the top and bottom of a flat
rail. This remarkable rail can be easily electrified using a
standard electric fence energiser.
Congratulations on your new Think Fencing
Zappa Rail Fence System.
Zappa Rail Fencing Features:
Installation Tips
We recommend a 4m post spacing. Zappa rail can
accommodate up to a 6m spacing.
We recommend stopping Zappa Rail and starting it again at
every corner to acieve the best result when tensioned.
When planning your Zappa Rail layout it is important to
construct suitable strainer assemblies. This can be done
using a conventional timber end assembly, pre-made steel
braced end stays or using Think Fencing’s end assembly kit.
End assemblies need to be included anywhere that the
fence changes in direction by over 45 degrees and where
end brackets or insulstrainers are attached.
If you need to join the Zappa Rail you can achieve this by
purchasing a Zappa Rail Joining Buckle or a Line Strainer
can be used.
Screwing the brackets in too hard can cause damage and
make it difficult for the Zappa Rail to slide through the
brackets.
When unrolling, Zappa Rail can appear wavy.
When tensioned it will straighten.
Zappa Rail is easier to install on a warmer day. We also
recommend re-tensioning the rail on the first warm day after
installation, to eliminate any warps or twists.
DIY
Installation
Lifetime
Warranty
Eco
Friendly
Australian
Made
ElectrifiableUV
Resistant
Electrifying
The black strip on the white Zappa Rail is the electrified side.
The black Zappa Rails electrified side is glossier than the
rest of the rail.
When you receive your Zappa Rail roll there is a sticker
pointing to the electrified side. Take note of this.
A standard electric fencing Energiser will work on Zappa Rail.
Expose a section of the electrifiable wire large enough to
enable you to connect an electric fence terminal lug. This
can be done with a sharp knife.
To electrify Zappa Rail when stopping and starting, expose
the electrifiable wire and use a connecting wire to join the
two together. This will ensure the conductivity continues.

Zappa Rail | Installation Guide 5
Drill with 8mm
Tek Head
Shifter or
20mm Spanner
Scissors or
Shape Knife
Safety Glasses Screwdriver Set Square
Wire CuttersPencilTape Measure
Tools Required.
What you will need
to get the job done.
Ratchet Angle Grinder/
Drop Saw

Zappa Rail | Installation Guide
6
Measure out your rail spacing. Spacing
between rails are varied based on your
specific requirements.
Attach both End Brackets directly to the
strainer post at your desired height using the
nut and bolt provided.
Refer to installation tips on end assembly construction
Screw the top of each bracket onto the posts
along the fence run using a Tek screw.
Do not screw the bottom of the bracket.
1
2
What you will need:
What you will need:
Option One - Line Strainer
Side BracketTop Bracket

Zappa Rail | Installation Guide 7
Roll the Zappa Rail out along the fence run.
Lift the Zappa Rail up into the bracket and
clip the bottom of bracket to hold in place.
3
4
Attach the Zappa Rail to the first end bracket.
Slide the Zappa Rail through cut out one then
back through cut out two. Make sure that at
least 100mm of Zappa Rail is pulled through
the End Bracket.
Cut out one Cut out two
Please note: Ensure that you have the
conductive wire orientated correctly to
suit your specific needs when electrified.

Zappa Rail | Installation Guide
8
6
Pull the Zappa Rail tight by hand and mark
where you need to cut the rail. Make sure
you leave an extra 1000mm to thread
through the End Bracket. Use a set square
to mark a square out. Cut both wires using
wire cutters, then using a sharp knife or
scissors cut through the plastic, or cut with
an angle grinder. What you will need:
Fasten the bottom screws into the top and
side brackets.
5
What you will need:

Zappa Rail | Installation Guide 9
8
Slide out the centre insert and rods from the
line strainer. Place the line strainer on the
centre of the Zappa Rail run then replace the
centre insert.
7
Attach the Zappa Rail to the second end
bracket keeping it as tight as possible.
Slide the Zappa Rail through cut out one then
back through cut out two. Make sure that at
least 1000mm of Zappa Rail is pulled through
the End Bracket. This will give you something
to pull tight.
Cut out oneCut out two

Zappa Rail | Installation Guide
10
9
Tension the Zappa Rail using two ratchets
(one on the top and one on the bottom).
Once tensioned hold in place using the rods
provided. What you will need:

Zappa Rail | Installation Guide 11

Zappa Rail | Installation Guide
12
Measure out your rail spacing. Spacing
between rails are varied based on your
specific requirements.
Attach the End Bracket directly to the
strainer post at your desired height using the
nut and bolt provided.
Refer to installation tips on end assembly construction
Attach the Insulstrainer at the same height
as the End Bracket. Put nut and bolt
(not supplied) through the middle of the
Insulstrainer and fasten using four Tek
screws on each corner of the Insulstrainer.
1
2
What you will need:
What you will need:
Option Two - Insulstrainer
Please Note: Depending on the size and
type of post you will need to obtain a
nut and bolt to go through the post and
centre hole of the Insulstrainer

Zappa Rail | Installation Guide 13
3
Roll the Zappa Rail out along the fence run.
Lift the Zappa Rail up into the bracket and
clip the bottom of bracket to hold in place.
Screw the top of each bracket onto the
posts along the fence run using a Tek screw.
Do not screw the bottom of the bracket.
4
What you will need:
Top Bracket Side Bracket
Please note: Ensure that you have the
conductive wire orientated correctly to
suit your specific needs when electrified.

Zappa Rail | Installation Guide
14
5
Attach the Zappa Rail to the end bracket.
Slide the Zappa Rail through cut out one then
back through cut out two. Make sure that at
least 100mm of Zappa Rail is pulled through
the End Bracket.
Cut out one Cut out two
Fasten the bottom screws into the top and
side brackets.
6
What you will need:

Zappa Rail | Installation Guide 15
8
Thread the Zappa Rail in-between the rod
and core of the Insulstrainer. Tighten using
a spanner on the top of the core bolt. The
Zappa Rail will wrap around the rod and core
creating tension.
If too much Zappa rail is wrapped around
core you will not be able to create sufficient
tension. In this case you must release the
tension cut off excess Zappa rail and re-
tension.
To release the tension you will need to
tighten the Insulstrainer with a spanner and
release the latch using a screwdriver. What you will need:
Please note: Do not put your fingers near
the latch when releasing tension.
7
Pull the Zappa Rail tight by hand and mark
where you need to cut the rail. Make sure
you leave an extra 1000mm to thread
through the End Bracket. Use a set square
to mark a square out. Cut both wires using
wire cutters, then using a sharp knife or
scissors cut through the plastic, or cut with
an angle grinder. What you will need:

Zappa Rail | Installation Guide
16
Joining Zappa Rail using a Line Strainer
To join Zappa Rail using the line starainer,
remove the rods then thread the two ends
through the line stainer ensuring that it is
overlapping at least 100mm.
Tension the Zappa Rail using two rachets (one
on the top and one on the bottom), then insert
rods to hold in place. What you will need:

Zappa Rail | Installation Guide 17
Slide the Zappa Rail in through the middle
cut out and back though the smaller cut out
on the same side.
Repeat for the other side.
Joining Zappa Rail using a Joining Buckle
One
Two Two

Zappa Rail | Installation Guide
18
Head Office:
2415 Geelong/Portarlington Road,
Portarlington, 3223 Victoria Australia
P. [phone]
E. [email protected]
www.thinkfencing.com.au