HOW TO BUILD A ZIP LINE - SECTION THREE - COMPONENT ASSEMBLY
TREE SAVER KIT
(AVAILABLE AS ADD-ON IF NOT INCLUDED IN THE KIT)
LAY OUT BLOCKS ON FLAT SURFACE TO ALIGN LARGER CABLE GROOVES. THREAD STRAP THROUGH CENTER HOLE IN EACH BLOCK.
WRAP STRAP & BLOCKS AROUND BASE OF TREE OR POLE. LIFT STRAP TO DESIRED ATTACHMENT HEIGHT. THREAD END OF STRAP THROUGH CAM, PRESS TAB TO PULL STRAP THROUGH, RELEASE IT TO SECURE THE STRAP IN PLACE.
WRAP CABLE AROUND BLOCKS, SECURING CABLE INTO BLOCK GROOVES.
TERMINATE CABLE WITH DESIGNATED HARDWARE.
WITH CABLE
THREAD CABLE SLING OR ZIP LINE CABLE THROUGH BLOCKS.
WRAP CABLE, BLOCKS AROUND TREE OR POLE. LIFT CABLE TO DESIRED ATTACHMENT HEIGHT.
TERMINATE CABLE WITH DESIGNATED HARDWARE.
HELPFUL HINT: DO NOT PUT CABLE DIRECTLY ON THE TREE. IF YOU DO NOT HAVE THE TREE SAVER KIT, PLACE UNTREATED WOOD BLOCKS UNDER THE CABLE TO PROTECT YOUR TREES. USE AS FEW BLOCKS AS POSSIBLE ON EACH TREE. USE PLENTY OF SPACE BETWEEN EACH BLOCK WITHOUT ALLOWING CABLE TO TOUCH BARK OF TREES.
STOP BLOCK
!!WARNING!! THE STOP BLOCK IS A SAFETY BACK-UP AT THE VERY END OF THE RIDE AND IS NOT A BRAKING SYSTEM. RIDERS SHOULD HAVE LITTLE TO NO SPEED WHEN THEIR TROLLEY MAKES CONTACT WITH THE STOP BLOCK.
STOP BLOCK MUST BE PLACED 5 FT. FROM END ANCHOR
MOUNT STOP BLOCK ONTO CABLE WITH RUBBER BUMPER FACING TOWARD MAIN LINE AND AT LEAST 5 FT. FROM THE ENDING ANCHOR. INSERT BOLTS THROUGH BLOCK AND WASHERS. TIGHTEN NUTS WITH A WRENCH.
RIDING GEAR
ONLY ATTACH CARABINERS TO THE ATTACHEMENT POINT OF TROLLEY.
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EACH RIDING GEAR ACCESSORY (E.G. HARNESS,SEAT, HANDLEBAR) MUST USE ITS OWN DEDICATED CARABINER ATTACHED DIRECTLY TO THE TROLLEY. |
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!!WARNING!! DO NOT CHAIN-LINK CARABINERS OR ATTACH MULTIPLE ACCESSORIES INTO ONE CARABINER. |
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BEFORE EACH RIDE, SQUEEZE-TEST CARABINERS TO ENSURE LOCKING GATE IS FULLY ENGAGED. |
SEATS
(AVAILABLE AS ADD-ON)
THE KNOTTHREAD THE ROPE THROUGH SEAT AND TWIST INTO A FIGURE-EIGHT. THREAD ROPE THROUGH ITSELF, PULLING 5-INCHES OF ROPE, MINIMUM. PULL UPPER HALF OF ROPE WHILE PUSHING DOWN ON KNOT TO CREATE A FLAT TOP. DO NOT USE SEAT WITH LESS THAN 5” OF ROPE FOLLOWING THE KNOT. |
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HELPFUL HINT FOR DRIFTER SEAT: A FRESH COAT OF OUTDOOR WOOD STAIN ONCE A YEAR AND KEEPING THE SEAT INDOORS WHILE NOT IN USE IS RECOMMENDED TO EXTEND SEAT LIFETIME.
!!WARNING!! ACCESSORIES SUCH AS HANDLEBAR OR HARNESS SHOULD NEVER BE ATTACHED TO THE SPLICED EYE OR THROUGH OPEN STRANDS ON THE ROPE. ACCESSORIES MUST ALWAYS BE CLIPPED DIRECTLY TO THE TROLLEY.
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!!WARNING!! ATTACHING ANY EXTRA ROPES OR CHAINS TO THE SEAT MAY RESULT IN BODILY HARM.
HARNESS
(AVAILABLE AS ADD-ON)
BEFORE EACH RIDE, SQUEEZE-TEST CARABINERS TO ENSURE LOCKING GATE IS FULLY ENGAGED.
THREAD LONG LOOP OF LANYARD THROUGH HARNESS TIE-IN LOOP THEN THREAD LANYARD SHORT LOOP THROUGH ITS LONG LOOP TO CREATE COW-HITCH KNOT.
ATTACH SHORT LOOP OF LANYARD TO TROLLEY WITH ONE CARABINER.
!!WARNING!! ALWAYS USE RIDING GEAR THAT IS DESIGNED FOR SAFETY-CRITICAL APPLICATIONS AND APPROVED FOR ZIP LINE USE.
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ALWAYS USE A HARNESS FOR ZIP LINES WHERE A FALL COULD RESULT IN INJURY. HARNESSES MUST BE CORRECTLY SIZED AND FITTED BASED ON THE AGE, SIZE AND BODY TYPE OF PARTICIPANT. WITH TIE-IN LOOP IN FRONT, STEP THROUGH WAIST LOOP, THEN LEG LOOPS OF HARNESS, AND PULL HARNESS UP TO WAIST. STRAIGHTEN CLOTHING UNDER HARNESS. TIGHTEN STRAPS FOR FIRM (NOT TIGHT) FIT. |
BUNGEE BRAKE SYSTEM
(AVAILABLE AS ADD-ON IF NOT INCLUDED IN THE KIT)
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MOUNT ON CABLE WITH RUBBER BUMPER FACING TOWARD MAIN LINE. INSERT BOLTS THROUGH BLOCK AND WASHERS. TIGHTEN NUTS WITH A WRENCH. ATTACH BUNGEE TO BRAKE BLOCK WITH QUICK LINK. TIGHTEN QUICK LINK WITH WRENCH. |
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SCREW THE EYE LAG SCREW INTO A TREE OR POST AT LEAST 10 FT. OFF TO THE SIDE OF THE ZIP LINE. WRAP BACK-UP CABLE SLING AROUND BRAKE ANCHOR. USE QUICK LINK TO CONNECT EYE LAG SCREW, CABLE SLING LOOPS AND BUNGEE. TIGHTEN QUICK LINK WITH WRENCH. |
HELPFUL HINT: DRILLING A 1/4” PILOT HOLE CAN BE HELPFUL FOR SCREWING EYE LAG SCREW INTO BRAKE ANCHOR TREE OR POST.
!!WARNING!! EYE-LAG SCREW MUST EMBED TO FULL DEPTH IN SOLID WOOD. SCRAPE AWAY ANY BARK THAT PREVENTS THE SCREW FROM EMBEDDING FULLY INTO WOOD.
!!WARNING!! NEVER USE A BUNGEE BRAKE WITHOUT A BACK-UP CABLE SLING.
!!WARNING!! DO NOT ATTEMPT TO RIDE YOUR ZIP LINE WITHOUT FIRST TESTING
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INSTALL THE BUNGEE AT LEAST 8 FT. UP THE BRAKE ANCHOR. !!WARNING!! BUNGEE MUST NOT STRETCH TO MORE THAN 175% ITS LENGTH. BUNGEE MAY FAIL AND INJURE ZIP LINE RIDER OR BYSTANDERS. |
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BRAKE BLOCK LOCATION
20-FT. BUNGEE BRAKE - 29.5 FT. AWAY FROM THE ENDING ANCHOR OR STOP BLOCK
30-FT. BUNGEE BRAKE - 47 FT. AWAY FROM THE ENDING ANCHOR OR STOP BLOCK.
LENGTH OF BUNGEE MINUS 3 FT. X 1.75 = DISTANCE FROM BUNGEE ANCHOR TO STOP BLOCK. 3 FT. TO ACCOUNT FOR KNOTS.
EXAMPLE: 20 FT. BUNGEE - 3 = 17 X 1.75 = 29.5 FT. OR 30 FT. BUNGEE - 3 = 27 FT. X 1.75 = 47 FT
!!WARNING!! DO NOT ALLOW BUNGEE TO SAG INTO THE RIDER’S WAY, IT CAN ENTANGLE THE RIDER.
SPRING BRAKE
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MOUNT ON CABLE BEFORE BOTH ENDS OF MAIN ZIP LINE ARE TERMINATED !!WARNING!! A STOP BLOCK MUST BE INSTALLED (SEE INSTRUCTIONS ON PAGE 32). COLLISION WITH SPRING WITHOUT STOP BLOCK MAY CAUSE INJURY OR DEATH. SPRING RESTS ON CABLE AT OR NEAR STOP BLOCK. !!WARNING!! NEVER USE MORE THAN 3% SLOPE WITH SPRING BRAKE. MULTIPLE SPRINGS MAY BE ADDED TOGETHER TO INCREASE STOPPING POWER. |
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BREAKHAWK
1 TURN BRAKEHAWK UPSIDE DOWN SO THAT YOU CAN SEE INTO THE CHANNEL. YOU WILL NOTICE SOME GROOVES CUT INTO ONE SIDE OF THE CHANNEL.
2 TURN YOUR ROGUE TROLLEY UPSIDE DOWN, SO THAT THE FLAT TOP PORTION IS FACING DOWN AND THE ROUNDED HEADS OF THE WHEEL RIVETS ARE FACING THE SAME SIDE AS THE GROOVES IN YOUR BRAKEHAWK.
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3 POSITION YOUR ROGUE TROLLEY INTO THE CHANNEL OF THE BRAKEHAWK. PUSH TROLLEY INTO THE CHANNEL UNTIL YOU HEAR AN AUDIBLE CLICK. YOU MAY NEED TO USE A RUBBER MALLET TO TAP THE TROLLEY INTO ITS SEATED POSITION. |
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4 ONCE THE TROLLEY HAS CLICKED INTO PLACE, RUN THE RETAINER PIN THROUGH THE HOLE IN THE CHANNEL (BETWEEN THE 5 RUN THE COTTER PIN THROUGH THE HOLE IN THE END OF THE RETAINER PIN. |
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6 WHEN YOU ARE READY TO USE, SIMPLY SET THE BRAKEHAWK & TROLLEY ON THE CABLE, ATTACH CARABINER CONNECTED TO LANYARD AND HARNESS.
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7 WHEN CABLE IS WET, ADD STRIP OF LEATHER (INCLUDED) BETWEEN RUBBER BRAKE PAD AND CABLE TO INCREASE STOPPING POWER.
!!WARNING!! DO NOT USE IN COMBINATION WITH OTHER BRAKING METHODS SUCH AS A BUNGEE BRAKE OR SPRING BRAKE. USING IN COMBINATION WITH AN IMPACT OBJECT CAN CRACK WELDS ON THE UNDERSIDE OF THE BRAKEHAWK.
!!WARNING!! ALWAYS USE A STOP BLOCK ON YOUR ZIP LINE, HOWEVER DO NOT PURPOSEFULLY IMPACT STOP BLOCK. IMPACTING STOP BLOCK WILL CRACK WELDS ON THE UNDERSIDE OF THE BRAKEHAWK.
!!WARNING!! DO NOT USE IF WELDS ON THE UNDERSIDE OF THE CHANNEL ARE CRACKED. SERIOUS INJURY CAN RESULT. RETIRE AND REPLACE BRAKEHAWK IMMEDIATELY.
NOTE:
INCREASE THE LIFESPAN OF YOUR RUBBER BRAKE PAD BY FLIPPING THE FRONT OF THE PAD TO THE REVERSE. AFTER BOTH FRONT AND REAR OF THE PAD ARE WORN, REPLACE. REPLACEMENT RUBBER PADS ARE SOLD SEPARATELY.
NOTE:
THE BRAKEHAWK TETHER IS A STRAP THAT HANGS DOWN FROM THE BRAKING SYSTEM ABOUT 10” WHICH THE RIDER CAN USE TO PULL DOWN TO STOP. SOLD SEPARATELY
