ProMark Offroad Blog
How to Eye Splice Synthetic Rope
Splicing is a great way to prepare new rope or repair used or broken synthetic ropes. Eye splicing is a fairly simple process. Follow these instructions and diagrams to eye splice a 12 strand synthetic winch rope. These instructions are available courtesy of www.ropeinc.com.
To learn more about our synthetic ropes, see our ProMark Offroad synthetic winch ropes for ATV and recovery winches.
Step 1 – Form Eye
Find the circumference of the rope and multiply this number by 7 (OR find the diameter of the rope and multiply by 21). Measure this distance from the end of the rope. Mark the distance with tape as ‘Mark A.’ Make sure the tape is wound around the rope tight enough to prevent the rope from unbraiding.
Make a loop at the end of the rope to form an eye. Wrap the rope around the metal thimble loop to find the correct eye size. Mark the point across from ‘Mark A’ as ‘Mark B’ with tape. Again, make sure the tape is tight around the rope.
Step 2 – Separate Strands
Tape the end of each separate strand. Unbraid the strands up to ‘Mark A.’ Be careful not to remove the twist from each individual strand.
Step 3 – Pair Strands
ProMark Synthetic Rope is compromised of 12 strands. Six of these strands are twisted to the left, and six strands are twisted to the right.
Tape together one left twist strand and one right twist strand. Repeat until all 12 strands are paired together. Pair strands that are close together as they emerge from the tape wrap at ‘Mark A.’
Step 4 – Mark Pairs
With the rope laid out and the eye formed, choose three pairs closest to the standing part of the rope and mark as #1, #2, and #3 respectively. Mark the remaining three pairs as #4, #5, and #6.
Step 5 – Insert Strands
Using a fid (tool used to splice rope), open the rope at ‘Mark B’ and insert strand pairs #1, #2, and #3 completely through the rope at right angles to the rope axis. Once strands #1, #2, and #3 are through the rope, pull each strand so that the taped end (Mark A) is snug against the body of the rope. It may be easier to pass the strand pairs through the rope one set at a time.
Step 6 – Initial Strand Tuck
Note that the rope braid pattern forms a line of strand crowns running parallel to the axis of rope.
- Starting with strand pair #1, select a row of crowns down the axis of the rope and tuck pair #1 over one strand and under two strands. Once tucked, pull out the slack in strand pair #1. Make only one tuck.
- Now tuck pair strands #2 and #3 in the same way. With each pair, select a crown row and tuck the individual pair over one strand and under two strands. Pull out the slack in each strand.
- With remaining pair strands #4, #5, and #6, select a crown row for each pair and make one tuck. Pull out the slack in each pair.
- Remove the tape wrap at ‘Mark A’ and gently but firmly pull on each of the strand pairs until ‘Mark A’ is snug to the base of the eye (Mark B).
- Now complete two more sets of tucks with each taped strand pair. Be sure to tuck each strand pair down the same crown strand line. Try to keep the twist in each pair, and continually remove slack from each strand pair after tucking.
Step 7 – Taper
- Cut off strand pairs #1, #3, and #5.
- Tuck strand pairs #2, #4, and #6 for an additional three tucks (over one and under two). Keep the twist in the strands and remove excess slack.
Step 8 – Final Tucks
- Split each strand pair (#2, #4, and #6) into two individual strands and tape each strand.
- Cut off one strand in each pair, leaving a short tail projecting from the last tuck.
- Tuck the remaining three single taped strands for three tucks (over one and under two), removing slack and keeping the twist.
- Now cut off the taped strands, leaving a short tail projecting, as shown.
How to Unbind Pinched Winch Cable
Use your truck or ATV to unbind a pinched winch cable.
Cable binding and pinching can happen for a number of reasons, for example, an off-kilter pull, loose wraps on the drum, or other improper winching techniques. In any of these cases, strands of cable can overlap, crisscross, pile up on one side of the drum, or get pinched in the winch housing.
How to Unbind Winch Cable
If the winch cable gets hopelessly pinched, to the point where freespooling is impossible, the first thing to try is to hook the winch cable to a tree or anchor point and pull it loose. Use a tree strap to attach the cable to the anchor point. Then back up the ATV or truck while powering out the winch. If that doesn’t work, try powering the winch in while you maintain backwards pressure with the vehicle.
Keep Safety in Mind
If the cable does not come loose right away, try powering in and out a few more times, but don’t work at it so long and hard that you damage the winch or vehicle. And don’t throw safety precautions out the wind. All the same winch safety rules still apply. Don’t jerk the cable. It’s not designed to withstand shock forces. Also, keep bystanders well away from the winching operation. Severe pinching and binding can weaken the cable and make it more susceptible to break. Use extreme caution when attempting to free a pinched winch cable.
Other Suggestions for Untangling Winch Cable
If pulling the cable out with your ATV or truck doesn’t work, you’re basically left with the option of taking your winch off the vehicle or trying to free the cable with a screwdriver or other tools. If your winch is behind the bumper, you may not be able to reach it with tools unless you remove the bumper and winch.
Once you get the cable loose, spool the line all the way out and inspect the cable for weak spots, snapped wires, or permanent kinks. Flex the cable to remove any temporary kinks or compression. Replace the cable if there is any sign of damage. Then respool the cable with the proper tension in tight, even layers.
How to Inspect Synthetic Winch Rope
If your synthetic rope shows signs of damage, replace it immediately.
A brand new synthetic winch rope will naturally “fuzz up” when you first use it. This fuzzy texture is considered a sign of normal wear. Instead of being something you should worry about, this roughing up is actually a good thing, because it protects the fibers underneath. The rope should quickly fuzz up and stabilize, without excessive roughing. If the surface of the rope continues to roughen up instead of stabilize, look for the source of excessive abrasion.
As you inspect the rope, take a close look at both the inner and outer layers of fiber. Signs of weakness, excessive abrasion, broken fibers, or other wear in either layer should alert you to obvious damage. Separate the strands to inspect the inner layers of the rope. If the fiber inside is powdery, the rope is significantly weakened and needs to be replaced.
When should you replace a synthetic winch rope?
Look for these signs of obvious damage:
- Significant abrasion anywhere along the length of the rope
- Two or more strands are cut
- Permanent flat areas or bumps (Flex the rope to eliminate these. If the flat area or bump is not eliminated by flexing, the rope is weak or damaged.)
- Large section of melted fibers (Look for a shiny appearance or stiff rope.)
Other changes in appearance, such as discoloration from chemical exposure (i.e. motor oil or fluids), may also be signs of weakness or damage. In short, if the appearance of the rope leaves you doubtful of its condition, ask for the opinion of a qualified technician or simply replace the rope. Better safe than sorry.
Electric Winch Maintenance Checklist
If you take good care of your electric winch, it will last for many years of use. Follow the winch maintenance checklist below to keep your winch in good working condition.
Winch Cable (Synthetic or Wire)
- Check for kinks, fraying, and other damage before and after each winching operation.
- Replace the cable immediately if you see signs of damage. Do not use a damaged rope.
- Keep the rope clean and dry.
- Spool the cable neatly and evenly onto the drum after you are done winching.
Electrical and Hardware
- Check the electrical connections every few months to make sure they are clean and tight.
- Remove dirt and corrosion from the electrical connections. If you allow the corrosion to build up, it may reduce the performance of your winch or cause a short.
- Power the cable in or out every few months, whether you need to use the winch or not. Periodically running the motor will create heat and dissipate any moisture built up in the motor. If the winch is not operated for a long period of time, this moisture will lead to internal corrosion and damage the motor.
- If you live and ride in salty areas, coat the electrical connections with silicone to prevent corrosion.
- Periodically check all mounting bolts for tightness.
Cleaning and Greasing
- The gearbox and drum bearings are permanently lubricated. No internal lubrication should be required for the life of the winch.
- If you take apart the winch for repair or cleaning, however, it will be necessary to re-lubricate the winch.
How to Rewind Winch Cable Under Load
After you’re done using your winch, it’s best to rewind the cable under load to spool it tight and even onto the drum. Ideally, there should be at least 500 pounds of tension on the cable. Here’s one way to get the job done:
Protect your winch hook and cable with a winch line stopper.
- Find an empty parking lot or open area with enough room to spool out most of the winch cable, leaving at least 5 wraps on the drum. Ideally you should be on a slight incline.
- Attach the winch hook to a tree, another vehicle, or a solid anchor point.
- Put the vehicle in neutral.
- Ask a friend to stand outside, in a position where he can see you (the driver) and see the winch cable as it wraps on the drum but where he is safely out of the cable’s path. Then have him direct you which way to turn the steering wheel as the winch pulls the vehicle towards the anchor point and the cable rewinds.
- Have your friend make sure that the cable winds in tight even, rows on the drum. If the cable starts to pile up on one side or become tangled, stop winching and power out the cable until the tangled rows are off the drum. Then respool in tight, even layers.
- Stop the winch when the vehicle is about 10 feet away from the anchor point.
- Let the tension out of the rope and disconnect the rope from the anchor.
- Attach the hook strap to the winch hook and hold on to the strap to spool in the rest of the cable. Do not put your fingers through the winch hook.
- Carefully spool in the remaining cable under light tension by pulling back on the rope while pulsing the winch remote.
- Attach the hook to one side under light tension, or—if you have a rubber stopper—spool in the cable until the hook is snug against the stopper. Do not power the winch hook into the fairlead without a rubber stopper, or you could damage the winch.
Why Does My Plow Slip Down? Winch Back-Driving and Cable Nesting
Lately we’ve been hearing from customers who are having problems with their ATV plow slipping down as the winch line creeps out. This problem can be caused by one of two things: 1) winch back-driving, or 2) cable nesting.
Troubleshooting Winch Creep on ATV Plows
If your ATV winch is controlled by a mechanical brake (and not a dynamic brake), there is a chance you may be experiencing back-driving when the plow is in the up position. Winches with mechanical brakes are designed to slip under excessive load to protect the winch gears. Under the weight of a heavy plow blade, the cable may slowly creep out and allow the blade to slip down a few inches.
If this happens, simply spool in the winch line to take up the slack. Using a snatch block can also reduce the load on the winch and prevent the plow from slipping.
Cable Nesting
Cable nesting is when the winch cable becomes tangled up on the drum like a bird’s nest. As you plow, the cable can slowly tighten around the drum as it works its way into the inner layers of cable.
If this happens, spool out the cable until all the messed up layers are unwound. Then spool the cable back onto the drum in tight, even rows.
How Do I Know if My Winch is Back-Driving or Nesting?
Since both back-driving and nesting cause the plow to slip, the two can easily be confused. The best way to find the cause of the problem is to observe the winch drum as the plow slips. If the drum turns, the problem is back-driving. If the drum does not turn as the winch line creeps, then the problem is cable nesting, where the winch line needs to be properly re-spooled around the drum.
Plow Winch Troubleshooting
| Symptom | Possible Causes | Solution |
| Winch line creeps out, causing the plow to slip down |
1. Winch back-driving 2. Cable nesting |
1. If drum turns, winch in slack, reduce load, or double line. 2. If drum does NOT turn, re-spool cable in tight, even rows. |
Related Posts:
Roller vs Hawse for Synthetic Plow Rope
10-foot Synthetic Rope for ATV Plows
With synthetic rope, it’s best to use an aluminum hawse fairlead. Aluminum is a softer material than steel, which means that you can sand it smooth if it happens to get any rough spots. As you raise and lower the plow, the synthetic cable may wear a groove in the aluminum hawse. If this happens, simply sand down the groove with fine grit paper.
This ability to sand down rough spots or gouges is what gives the aluminum hawse an advantage over the steel roller. The chrome finish on a roller fairlead prevents you from being able to sand it down. If you use a roller fairlead with your synthetic rope, any sharp edges that develop can shred the rope, and the only way to prevent this is to replace the roughed-up fairlead with a new one.
Use an aluminum hawse with synthetic rope.
Another important part of maintaining a synthetic plow rope is to keep the rope free of debris that could scuff up the hawse. Abrasive material on the rope can cause the rope to break if it rubs on the hawse.
Also, watch the angle of the rope as it raises and lowers the plow. A steep angle can cause premature wear on the rope. Make sure the rope isn’t rubbing on any edges, such as the winch housing, plow parts, or the ATV.
Winch Cable for Plowing
10-foot Synthetic Winch Cable for Plowing
Use a shorter cable length instead of the longer cable you use for off road recovery. It’s cheaper and easier to replace if it breaks. Shorter cable means there’s less chance of binding. Plus, you get more power from the winch because it’s pulling from the bottom layers of cable.
To prevent cable wear, don’t lift the plow all the way off the ground. Four to six inches should be enough clearance to get around. Lifting the plow all the way up places unnecessary stress on the cable, which causes it to fray, weaken, and eventually break.
Don’t let the winch cable rub on the bumper, winch housing, or other sharp edges. Use a winch saver sheath to protect the cable near the hook. The sheath will help prevent excessive fraying or rubbing.
If you switch from steel cable to synthetic rope for plowing, make sure you use a brand new fairlead. The frays and burrs on the old fairlead will cut into your new synthetic rope and destroy it in no time. If the synthetic cable gets wet, spool it out after you’re done and let it dry completely before spooling it back in.
Winch Cable Replacement
Next time you replace your winch cable, you may want to consider synthetic rope.
Inspecting your winch line is one of the most important steps in winch maintenance and safety. It only takes a few minutes, but it could prevent some big headaches in the long run.
Do a quick inspection before and after using your winch. Check for weak spots in the cable. Watch for excessive fraying or crimping and other signs of damage that could signal the need for a new cable. Do a more thorough inspection as part of your regular winch maintenance. How often you need to inspect the cable depends on how often you use your winch.
Although electric winches are designed to last for years, your cable should generally be replaced every two to three years. If you wait until your cable breaks to replace it, you’re risking your life and the lives of those around you. Don’t take your chances with a weakening cable.
When the time comes to replace your winch cable, make sure you find a cable with the correct thickness and length. You may also want to consider switching to synthetic winch rope for added safety.
Winch Cable Replacement: How to Replace Steel Cable with Synthetic Winch Rope
Follow these step-by-step instructions to install your new synthetic winch rope.
Insert synthetic cable through drum opening.
Remove the wire rope. Release the clutch and unspool the cable. Wear gloves to protect your hands from burrs on the cable.
(Note: Some steel cables are attached to the drum with a metal button or bolt. If so, remove this button or bolt. You will not need it to install the synthetic winch rope.)
Step 2.
Insert the end of the synthetic cable through the small hole in the winch drum. You may need to use a small screwdriver or other tool to nudge the rope all the way through the hole.
Step 3.
Secure the synthetic cable to the winch drum.
Pull the cable through the hole, and wrap the end of the cable around the underside of the drum.
Step 4.
Wrap the cable around the drum and over the top.
Step 5.
Tuck the cable underneath itself where it first exits the small drum hole.
Step 6.
Snug the end of the synthetic cable underneath the cable where it exits the drum hole so that it depresses into the opening in the drum.
Step 7.
Pull the long end of the cable snug to secure the winch cable to the drum. The cable should now be securely attached to the winch drum.
Step 8.
Spool the synthetic rope onto the drum using the power in / power out buttons on the winch control. Keep tension on the rope so that the rope winds tight against the drum. Make sure the rope spools in tight, even rows to prevent the layers from overlapping.
(Note: Install the cable so that it spools out from the bottom of the drum.)
Step 9.
If the synthetic rope is too long for the size of your winch drum, you may need to trim the excess rope for the correct fit. For instructions on splicing a new eye, see the article on Splicing Synthetic Rope.
Note: These instructions are tailored for the installation of Blue Steel synthetic rope. Other types of cable rope may require additional modifications.
Article source: Blue Steel Synthetic Cables (pdf)
