Build stalls with a kreg jig instead of steel channels

My stall walls are secured in a 2x2 board channel as well. They’ve taken a lot of abuse over the 30+ years they’ve been there and no issues. We’ve taken down the stall walls a couple of times for various reasons and reassembling has been easy.

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That looks great!

Add me to those who think it would be too weak. I built a chicken coop last year using a kreg jig, and while it’s just fine to contain chickens, I wouldn’t want to trust it with horses. My channels are 2x4, and the boards for the wall are 2x12 rough cut, and are 4 feet high with no bars or grates above them. There has been no damage from kicking. The top board between my 12 hand pony and arthritic retiree is slightly too short, so if they nudge it all the way to the front or back, it can come out. This happens from time to time so I am just guessing how it happens. Neither seems alarmed by it, and it’s very easy to just pop back in, where it’s good for another few months until it happens again. I realize this could easily be remedied, but I haven’t gotten around to it yet.

You can use them no problem if you run a groove down both edges and use splines…I’d use 1/2" plywood for those…to emulate the T&G and provide the strength/unity that you need to have across the wall. The boards without T&G/splines/ship-lap will break far easier from a good kick than those that have those features.

Now don’t rule out obtaining T&G boards. Your local, independent full service lumber yard should be able to get you the 2x T&G material since it’s also used in some flooring applications for sub-flooring instead of plywood. They may just need to order it in for you.