HOW TO BUILD A ZIP LINE - SECTION TWO - CABLE INSTALLATION

THE MAXIMUM ALLOWABLE SLOPE IS 3% (3 FT. DROP PER 100 FT. OF DISTANCE) FOR ZIP LINES THAT WILL NOT UTILIZE A BUNGEE BRAKE (A STOP BLOCK IS NOT A BRAKING SYSTEM). THE MAXIMUM ALLOWABLE SLOPE IS 6% (6 FT. DROP PER 100 FT. OF DISTANCE) FOR ZIPLINES THAT UTILIZE A BUNGEE BRAKE.

!!WARNING!! ZIP LINE MUST NEVER EXCEED 6% RIDING SLOPE. HIGH SPEED COLLISION WITH END POINT MAY CAUSE INJURY OR DEATH.

 

CHETCO, HORNET, SPRING & 1/4" CABLE KITS

ONE TURNBUCKLE ZIP LINE KITS

 

 

 

1 UNSCREW NUTS OR PULL COTTER PINS FROM BOLTS. DRAW BOLTS FROM TURNBUCKLE JAWS.

2 ASSEMBLE TURNBUCKLE BY SCREWING SHAFTS UNTIL EXTENDED AS SHOWN. R WITH R, L WITH L (REVERSE THREADS). TURNBACKLE MUST HAVE FULL THREAD ENGAGEMENT AT ALL TIMES.

3 WRAP CABLE SLING AROUND ANCHOR (FOR TREE SAVERS SEE SECTION 3). 4 PLACE LOOP ENDS OF SLING INTO TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN. 5 PLACE THIMBLE END OF MAIN CABLE INTO OTHER TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN

6 THREAD CABLE THROUGH CHETCO TROLLEY AND A CABLE CLAMP. WRAP CABLE AROUND ANCHOR AND THREAD BACK THROUGH CLAMP.
NOTE: IF YOU HAVE A SPRING BRAKE, LOAD ONTO CABLE ON DOWNHILL SIDE OF TROLLEY.

7 TENSION ZIP LINE CABLE BY PULLING ON DEAD END OF CABLE OR BY USING TENSIONER KIT (ADD-ON ITEM).

8 PULL CABLE TAUT. U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE. TIGHTEN CABLE CLAMPS MODERATELY PAST SNUG (≈ 15 FT. LBS) 1-2 INCHES APART.

!!WARNING!! NEVER ATTEMPT TO RIDE OF APPLY WEIGHT TO ZIP LINE BEFORE WEIGHT TEST OR WHILE TENSION REMAINS ON TENSIONING WINCH.

9 CRANK TURNBUCKLE IF CABLE NEEDS MORE TENSION.

10 INSTALL TURNBUCKLE BACK-UP CABLES. THREAD BOTH ENDS OF CABLE SECTION THROUGH CABLE EYES AND SECURE WITH CABLE CLAMPS. IT'S IMPORTANT TO TAKE UP AS MUCH SLACK AS POSSIBLE BEFORE FINAL CLAMPING.

HELPFUL HINT: IN THE CHETCO, BLACK RAPTOR, HORNET AND SPRING KITS, THE TURNBUCKLE BACK-UP CABLES ARE 5/16’’, TORQUE THE CABLE CLAMPS ON THE BACK-UP CABLES TO 30 FT.LBS.

 

 

ZIP LINE LENGTH	RECOMMENDED CABLE SIZE	CLAMP TORQUE
UP TO 200'	1/4"	15 LBS.
UP TO 500'	5/16"	30 LBS.
UP TO 1000'	3/8"	45 LBS.

 

 

 

 

ROGUE SERIES, ULTIMATE TORPEDO, 5/16" & 3/8" CABLE KITS

TWO TURNBUCKLE ZIP LINE KITS

 

  

 

1 UNSCREW NUTS OR PULL COTTER PINS FROM BOLTS. DRAW BOLTS FROM TURNBUCKLE JAWS.

2 ASSEMBLE TURNBUCKLE BY SCREWING SHAFTS UNTIL EXTENDED AS SHOWN. R WITH R, L WITH L (REVERSE THREADS). TURNBUCKLE MUST HAVE FULL THREAD ENGAGEMENT AT ALL TIMES.

3 WRAP CABLE SLING AROUND ANCHOR (FOR TREE SAVERS SEE SECTION 3).

 

4 PLACE LOOP ENDS OF SLING INTO TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN.

5 PLACE THIMBLE-END OF MAIN CABLE INTO OTHER TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN.

6 IF TENSION IS USED, ATTACH WINCH TO SECOND ANCHOR WITH LANYARD AND CABLE GRAB TO CABLE. TENSION MAIN ZIP LINE CABLE. (TENSIONING KIT INSTRUCTIONS SEE PAGES AT HERE) 7 WRAP CABLE SLING AROUND ANCHOR AT CALCULATED HEIGHT, CONNECT TURNBUCKLE TO CABLE SLING LOOPS AND SECURE WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN.

8 THREAD TURNBUCKLE BOLT THROUGH THIMBLE AND SECURE WITH BOLT OR COTTER PIN. USE A WRENCH OR PLIERS TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN. THREAD MAIN CABLE FIRST THROUGH THREE CABLE CLAMPS, AROUND THIMBLE AND BACK THROUGH CABLE CLAMPS.

!!WARNING!! NEVER ATTEMPT TO RIDE OR APPLY WEIGHT TO ZIP LINE WHILE TENSION REMAINS ON WINCH.

9 PULL CABLE TAUT. U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE. TIGHTEN CABLE CLAMPS MODERATELY PAST SNUG, FOR ROGUE SERIES OR 5/16" CABLE (≈ 30 FT. LBS), FOR 3/8” CABLE (≈ 45 FT. LBS) AT 1-2 INCHES APART.

10 INSTALL TURNBUCKLE BACK-UP CABLES. BACK-UP CABLE MUST THREAD THROUGH CABLE LOOPS ON BOTH SIDES. IT'S IMPORTANT TO TAKE UP AS MUCH SLACK AS POSSIBLE BEFORE FINAL CLAMPING.

11 IF USING A TENSIONING KIT, RELEASE TENSION AND TRANSFER LOAD TO MAIN ZIP LINE.

 

 

 

 

ROGUE PRO KIT

 

1 WRAP CABLE SLING AROUND ANCHOR. PULL UP TO DESIGNATED HEIGHT.

CONNECT LOOPS OF CABLE SLING TO 9/16 QUICK LINK AT CALCULATED HEIGHT, CONNECT QUICK LINK TO LOOP OF MAIN CABLE. TIGHTEN QUICK LINK WITH WRENCH.

DISTANCE BETWEEN QUICK LINK AND TREE MUST BE AT LEAST HALF THE TREE’S DIAMETER. IF THE CABLE SLING ISN’T LONG ENOUGH, CALL US AND ASK FOR A CUSTOM CABLE SLING.

2 UNROLL CABLE ACROSS CABLE AVENUE TO OPPOSITE ANCHOR. 

 

 

TENSIONING KIT

 

3 TO EXTEND TENSIONING KIT: PUT DIRECTION SWITCH INTO NEUTRAL. PUSH RATCHET SWITCH TO DISENGAGE GEAR WHILE PULLING OUT CABLE TO UNWIND.

HELPFUL HINT: IF RATCHET RESISTS, PUT DIRECTION SWITCH IN THE DOWN POSITION AND USE THE RATCHET HANDLE TO PUSH PAST RESISTANCE.

4 WRAP TENSIONER STRAP AROUND SECOND ANCHOR, ABOUT A FOOT OVER CALCULATED ZIP LINE HEIGHT, AND HOOK TENSIONER IN STRAP LOOPS. OPEN GRAB BY PUSHING SHAFT TOWARD JAW. ATTACH CABLE GRAB TO CABLE. 

5 CLOSE LATCH TO LOCK CABLE IN PLACE.

6. SWITCH DIRECTION SWITCH TO "UP" (U). CRANK HANDLE TO TENSION UNTIL ZIP LINE CABLE IS LIFTED OFF GROUND TO APPROPRIATE HEIGHT. 

 

!!WARNING!! NEVER ATTEMPT TO TENSION ZIP LINE WHILE WINCH IS SWITCHED TO "DOWN"(D) POSITION.

7 WRAP SECOND CABLE SLING AROUND ANCHOR AT CALCULATED HEIGHT, CONNECT TO THIMBLE AND 9/16 QUICK LINK. TIGHTEN QUICK LINK WITH WRENCH. 

8 THREAD CABLE THROUGH QUICK LINK, AROUND THIMBLE AND BACK ON ITSELF, PULLING TAUT. SECURE WITH CAMBLE CLAMPS. U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE AND THE SADDLE PRESS AGAINST LIVE END OF THE CABLE. 

9 CLAMPS SHOULD BE SPACED 1 TO 2 INCHES APART AND MUST BE TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS).

!!WARNING!! ZIP LINE MUST NEVER EXCEED 6% RIDING SLOPE. HIGH SPEED COLLISION WITH END POINT MAY CAUSE INJURY OR DEATH.

10 RELEASE WINCH TENSION BY FLIPPING SWITCH TO "DOWN" (D) AND CRANKING THE HANDLE.

 

TENSION WILL TRANSFER TO MAIN CABLE AND TENSIONING KIT WILL HANG SLACK. REMOVE GRAB BY PUSHING FORWARD. REMOVE TENSIONING KIT AND STRAP.

 

 

 

 

SLEADD KITS

 

1/2", 11/16" AND 7/8" WRENCHES (INCLUDED)

3/16” HEX KEY (INCLUDED)

GLOVES (NOT INCLUDED)

 

THE CABLE SLING, TRI-LINK™ AND WINCH CAN BE INSTALLED ON EITHER END OF THE ZIP LINE. BE AWARE THAT THESE COMPONENTS WILL TAKE UP 3-4 FT. OF LENGTH; DECIDE WHICH END WILL BE MOST PRACTICAL FOR YOUR RIDERS.

150LX AND 250LX KITS

THREAD CABLE SLING THROUGH CENTER HOLES OF 8 TREE-SAVER BLOCKS.

WRAP CABLE SLING AROUND ANCHOR. PULL UP TO DESIGNATED HEIGHT. CREATE LOOP AT OPEN END OF CABLE SLING AND ADJUST SO LOOPS OF SLING MEET AT A DISTANCE HALF OF THE ANCHOR’S DIAMETER.

 

	CLAMP END OF CABLE SLING INTO SMALL LOOP USING THREE CABLE CLAMPS. CLAMPS SHOULD BE SPACED 1 TO 2 INCHES APART AND MUST BE TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS).
	U-BOLT OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE AND THE SADDLE PRESS AGAINST LIVE END OF THE CABLE.

 

CONNECT HOOK ON WINCH TO ATTACHMENT POINT LABELED ‘WINCH’ ON TRI-LINK™.

 

CONNECT CABLE SLING LOOPS USING A 9/16 QUICK LINK TO ATTACHMENT POINT LABELED 'ANCHOR' ON TRI-LINK™ MAKING SURE TO ORIENT TRI-LINK™ WITH ATTACHMENT POINT LABELED 'MAIN' ON TOP. TIGHTEN 9/16 QUICK LINK USING COMBINATION WRENCH.

UNROLL CABLE ACROSS CABLE AVENUE TO OPPOSITE ANCHOR.

 

 HELPFUL HINT: USE PIPE OR BROOM HANDLE IN CENTER HOLE OF SPOOL TO MAKE UNWINDING EASIER.

THREAD CABLE THROUGH CENTER HOLES OF 8 TREE-SAVER BLOCKS

 

WRAP CABLE AROUND OPPOSITE ANCHOR AT DESIGNATED HEIGHT.

PULL AS TIGHT AS POSSIBLE BY HAND, IDEALLY UNTIL THE ENTIRE LENGTH OF CABLE IS OFF THE GROUND. BE SURE TO WEAR GLOVES. HAVE A FRIEND SECURE CABLE IN PLACE AROUND ANCHOR WITH THREE CABLE CLAMPS.

 

CLAMPS SHOULD BE SPACED 1 TO 2 INCHES APART AND MUST BE TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS).

U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE AND THE SADDLE PORTION MUST PRESS AGAINST THE LIVE END OF THE CABLE.

 

TROLLEY ASEEMBLY

PLACE WHEELED PORTION OF TROLLEY OVER CABLE. SLIDE HANDLEBAR COLLAR UP INTO SIDE PLATES.

INSERT TWO BOLTS THROUGH TROLLEY AND HANDLEBAR COLLAR. SECURE WITH NUTS. TIGHTEN HEX BOLTS MODERATELY TIGHT (≈20 FT. LBS) WITH PROVIDED WRENCHES.

 

 

 

 

 

TENSIONING SLEADD KITS

 

SWITCH DIRECTION SWITCH TO "UP" (U) POSITION. CRANK TO TENSION CABLE.

!!WARNING!! NEVER ATTEMPT TO TENSION ZIP LINE WHILE WINCH IS SWITCHED TO "DOWN"(D) POSITION.

WHEN ZIP LINE IS TIGHTENED TO DESIRED TENSION, CLAMP SHORT TRI-LINK™ CABLE TO MAIN CABLE IN FRONT OF WINCH USING FOUR FIST GRIPS.

FIST GRIPS MUST BE SPACED 1 TO 2 INCHES APART AND TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS).

 

!!WARNING!! NEVER ATTEMPT TO RIDE OR APPLY WEIGHT TO ZIP LINE WHILE TENSION REMAINS ON WINCH.

SWITCH DIRECTION SWITCH TO "DOWN" (D) POSITION. CRANK TO DETENSION WINCH.

	WINCH WILL HANG LOOSE WHEN ALL TENSION HAS TRANSFERRED TO TRILINK CABLE.
	OPTIONAL: USE INCLUDED HOOK-AND-EYE STRAP TO FASTEN WINCH HANDLE TO QUICK LINK. THIS WILL SECURE THE HANDLE FROM JOSTLING DURING ZIP LINE RIDES.

 

 

 

 

 

ALTERNATE TERMINATION STYLES

 

ATTENTION CHETCO TROLLEY OWNERS - HELPFUL HINT: WE RECOMMEND PULLING THE CABLE THOUGH THE CHETCO TROLLEY BEFORE TERMINATING THE CABLE ON BOTH ENDS.

 

RAW CABLE WITH CLAMPS

THE SIMPLEST CONNECTION IS TO WRAP RAW CABLE AROUND END  ANCHOR, THEN USE THREE CLAMPS TO TERMINATE THE LINE.

 

TURNBUCKLES AND SLINGS

WHEN USING A TURNBUCKLES A) ATTACH TO CABLE SLING WRAPPED AROUND ANCHOR OR  B) ATTACH TO EYEBOLT. ALWAYS INSTALL TURNBUCKLE BACK-UP CABLES. SEE PAGE HERE FOR MORE DETAILS ABOUT TURNBUCKLE INSTALLATION.

 

EYEBOLTS & QUICK LINKS

EYEBOLTS ARE IDEAL FOR WOOD OR METAL POLES. THE EYEBOLT MUST BE LONG ENOUGH TO HAVE THREADS PROTRUDE THROUGH POLE, WASHER AND NUT, AND HAVE A PROPER STRENGTH RATING. CABLE CONNECTS TO EYEBOLT BY A) THREADING THROUGH EYEBOLT, AROUND A THIMBLE AND TERMINATING WITH THREE CLAMPS OR B) ADDING A QUICK LINK TO EYEBOLT, THEN THREADING CABLE THROUGH QUICK LINK, AROUND THIMBLE AND TERMINATING WITH THREE CLAMPS.

NOTE: A QUICK LINK, WITH PROPER STRENGTH RATING CAN BE USED FOR 1/4” & 5/16” CABLE. A 3/8” DIAMETER CABLE MUST CONNECT USING A) TURNBUCKLE, B) A SHACKLE WITH PROPER STRENGTH RATING OR C) BY DIRECTLY WRAPPING AROUND ANCHOR AS RAW CABLE. A 1/2” DIAMETER CABLE MUST CONNECT TO ANCHOR AS RAW CABLE ONLY.

CALL US IF YOU HAVE QUESTIONS ABOUT TERMINATING ZIP LINE CABLE .