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.

 

CHETCO & 1/4" CABLE 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).

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.

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.

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.

HELPFUL HINT: IN CHETCO KIT, 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 OR - 5/16" & 3/8" CABLE 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).

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. ATTACH WINCH TO SECOND ANCHOR WITH LANYARD AND CABLE GRAB TO CABLE. TENSION ZIP LINE. (FOR TENSIONING KIT FLIP TO ROGUE-PRO INSTRUCTIONS)

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

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.

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.

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. 

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).

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

ASSEMBLY 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.

NEVER ATTEMPTED 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).

 

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

ONE OF THE MOST SIMPLE CONNECTIONS IS JUST A LENGTH OF RAW CABLE TERMINATED WITH AT LEAST 3 CABLE CLAMPS PER SIDE. THIS TERMINATION METHOD IS IDEAL WHEN USING TREES.

 

TURNBUCKLES AND SLINGS

TURNBUCKLES CAN BE UTILIZED FOR FINER CABLE TENSION ADJUSTMENTS. WHEN USING A TURNBUCKLE, ATTACH IT TO A CABLE SLING WRAPPED AROUND THE ANCHOR, OR TO AN EYEBOLT.

ALWAYS INSTALL TURNBUCKLE BACK-UP CABLES. BACK-UP CABLE MUST THREAD THROUGH CABLE LOOPS ON BOTH SIDES.

 

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. A THIMBLE MUST BE USED TO CREATE THE TIGHT CONNECTION LOOP ON THE ZIPLINE CABLE. THE QUICK LINK IS OPTIONAL, BUT MUST HAVE THE STRENGTH RATING EQUAL TO OR GREATER THAN THE ZIPLINE CABLE. A QUICK LINK MAY ALSO BE USED TO CONNECT THE CABLE TO THE SLING INSTEAD OF TURNBUCKLE.