Grab a *.elf file ( HackMii Installer's boot.elf works) and put that in the root of the SD card.Copy the 'private' folder from the Smash Stack download to the root of the SD card.Connect the SD card to your computer and rename the 'private' folder to 'privateold' in the root of the SD card.Smash Stack will not work if the console has any custom stages on it, even the three samples that come with a new file or the stages from the Smash Service. Go to the stage builder, move any existing custom stages on Brawl to your SD card, and exit the stage builder.
You must have an SD card that is 2GB or less.
Note: An SDHC card will not work with Super Smash Brothers Brawl.