Exhibition Models: IRT Horse Air Stall

The Project by the Numbers

• 4 Bespoke Air Stall Models

• 2,500+ Hand-Drilled Brass Rivets

• 400+ Precision Resin 3D-Printed Components

• 112 Integrated Neodymium Magnets

• 72 Fully Functioning Moving Parts

• 12 Custom-Painted Thoroughbred Horses

The Brief

IRT, a global leader in international horse transport, required four flawless exhibition display models of their specialized horse air stalls used for shipping world-class thoroughbred racehorses.

These weren't just static showpieces; they needed to serve as active, hands-on demonstration tools worldwide. The crucial requirement? Every single moving and removable part had to function exactly like its full-scale counterpart.

Operating with zero technical drawings, our team reverse-engineered the entire structure solely from a collection of reference photographs and basic external dimensions.

The Funky Lemon Solution

To achieve true-to-life mechanics and premium durability at a 1:6 scale, we combined traditional bench craftsmanship with high-tech fabrication:

• Pure Reverse Engineering: The main chassis, interior walls, and doors were engineered from laser-cut acrylic panels and custom extrusions, with all structural panel lines precisely etched during the laser process.

• Meticulous Hand-Assembly: To capture the industrial build of the real stalls, we individually drilled and hand-glued over 600 tiny brass rivets per stall. Roof and door panels were hung using brass piano hinges, glued and pinned to guarantee incredible structural strength and fluid movement.

• Modular "Peg & Groove" Architecture: Just like the real stalls, the interior walls and sliding partitions configuration can be changed on the fly. We engineered a seamless peg-and-groove track system into the floors and ceilings, allowing doors to slide, pivot, and slot in or out effortlessly to demonstrate horse loading safety.

• Tactile Material Finishes: To mimic the industrial rubber padding of the real stalls, we applied a specialized rubberized coating to the interior wall pads, door stoppers, handles, and large door treads. The main floor was outfitted with a rugged, scratch-proof lining to withstand constant interactive use.

• Magnetic Rigidity: We embedded 28 powerful neodymium magnets per stall into the door frames and rear locking bars. This ensures the heavy-duty doors snap shut with a satisfying click and stay securely closed without flapping.

Artisan Partnership: Custom Thoroughbreds

To complete the realism, the 12 scale horses supplied with the models were sent to the specialists at Magpie Model Horses. They meticulously hand-painted every horse to match IRT's exact color specifications—down to individual hair color variations—and finished them with custom-branded reins mirroring IRT’s corporate identity.

Micro-Precision 3D Printing

For the intricate hardware, we utilized our in-house DLP (Digital Light Processing) UV resin 3D printers. This high-resolution tech allowed us to manufacture nearly 100 hyper-detailed components per stall—including custom strap buckles, tie-downs, and structural hardware—that standard 3D printers simply cannot resolve at this scale.

Built for Global Transit: Bespoke Flight Packaging

With units destined for Australia, the USA, and the UK, the packaging had to be bulletproof. We engineered a complete, heavy-duty transit ecosystem for each model:

• The Transit Tray & Case: Each box was built from 9mm interlocking laser-cut MDF, reinforced with 2x1 inch pine battens. To eliminate the risk of dropping the model while lifting it out, we engineered an internal sliding tray with integrated foam padding and a heavy-duty pull strap.

• The Foam "Crown": We sculpted a custom soft-foam crown that slides directly over the top of the model. This creates a perfectly snug fit inside the crate, locking all external doors tightly in place and eliminating any movement or rattle during international freight.

• Internal Bracing & Horse Inserts: Custom foam blocks were designed to slot directly into the stall interiors, locking the modular walls and sliding doors rigidly in place. Furthermore, every single horse received a custom-cut foam dock, allowing them to travel safely inside the model without risk of collision.

Complete Client Documentation

To ensure the IRT global sales teams could seamlessly operate and pack the units, Funky Lemon supplied a comprehensive, step-by-step photographic instruction manual. This clearly detailed the removal and installation of the internal partitions, alongside strict packing guidelines to preserve the longevity of these high-end marketing assets.