How Do I Install a FLIGHT Stack System?

Learn the install sequence for FLIGHT Stack, from steel frame setup and tread pan alignment to wood tread assembly, LEDs, and Vedera glass.

FLIGHT Stack installs in two main phases. First, the steel frame and tread pans go in. Then the wood treads, anti-runs, glass, and finish details complete the stair.

Some projects ship in a steel-first sequence. In those cases, the stringers, tread pans, temporary treads, and plywood glass templates go in first. The finished wood and glass install later.

Viewrail builds each system to your project drawings. The install depends on templates, tread pan alignment, and a tight finish sequence.

FLIGHT Stack is not a DIY FLIGHT system. Use the project drawings and installer instructions provided with your order.

Installation overview

These are the main stages of a FLIGHT Stack installation. Your project package includes the exact measurements, hardware, and tread labels for your stair.

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Step 1: Set the header template and prep the attachment points

Mark the plywood header template location from the finished-floor reference on your drawings. Fasten the template directly to structural blocking, then predrill the outside holes.

If finish flooring is not installed yet, build up the stringer feet and lower tread pan locations to match the final floor thickness. For wall-side installs, mount the plywood stringer template to the wall backing before the steel goes up.

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Step 2: Hang the steel stringers and verify geometry

Attach the header brackets to the stringers. Raise the stringers into place and fix them at the header.

For wall-side installs, lag the stringer to the wall template. Then check each stringer for plumb on all three axes and confirm the top rise is 1 inch long to account for the finished tread thickness.

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Step 3: Install tread pans in sequence

Assemble each tread pan with its gasket set first. Then install the first tread pan, level it, recess it 1/16 inch from the top and front edges of the stringers, and torque the hardware.

Continue down the run one pan at a time. Add the required polycarbonate shims between pans, square up the new pan, then return to torque the previous one. Repeat that pattern until the top tread pan is installed.

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Step 4: Finish the steel-first phase

Predrill the remaining header holes, install the header frame brace, and secure the first and second tread pans with the lag screws shown on the drawings.

If the steel ships before the finished wood and glass, the stair can serve as a temporary stair after this phase. Temporary 2x12 treads can be added until the finish package arrives.

The steel-first install also includes the temporary plywood glass templates and early Vedera mounting hardware. Those temporary parts come off before the finished tread and glass phase begins.

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Step 5: Route LEDs if included, then install the wood tread assemblies

If your stair includes LEDs, remove any temporary parts first, drill the harness access hole, and have a licensed electrician connect the controller and power supply. Then run the loomed stringer harness through the tread pans.

Start at the top tread. Dry fit, scribe if needed, apply adhesive, route the LED harness, and fasten the rise-and-run assembly from underneath.

Then drill the pilot holes that tie each lower tread to the riser above, connect the tread harness to the main stringer harness, test the LED strip if needed, and repeat that pattern as you work down the stair.

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Step 6: Install anti-runs and anti-rises

Once the tread assemblies are in, glue the frame brace in place and install the anti-run and anti-rise parts from the bottom up. Clamp them, fasten them from inside the tread pans, and let the adhesive cure.

If the LED power supply is installed inside the first tread, do not use construction adhesive where future access is required.

After that, check tread alignment and sand any proud edges. Then apply the tread gaskets and slide nylon bushings over the exposed bolts.

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Step 7: Install Vedera glass and finish details

Use the glass labels and drawings to place each panel. Add the Vedera gaskets, plates, O-rings, and pin end caps, then hand-tighten the nuts so the panels can still be adjusted.

Once all panels are in, align them to a 1-inch gap unless your drawings say otherwise. Tighten the first and last nut on each pin first, then finish torquing all Vedera pin nuts to 23 lb-ft.

Install the wood cover caps over each pin. If your stair includes lighting, pair the wall remote and test on, off, dimming, and color temperature before final cleanup.

Related topics

• Choose Your FLIGHT Style — Compare Stack with other FLIGHT systems.
• How Can I Customize My FLIGHT Staircase? — Review the full FLIGHT planning path.
• Choose a FLIGHT Glass Railing Style — Compare Vedera with other stair glass options.
• How Do I Maintain Glass Railing? — Keep the glass clean after install.