Have you ever wondered how to correctly install wire rope clips and what the phrase "Never saddle a dead horse." means? Below you will find our informative video explaining these things.
If you need help selecting the best wire rope clip for your project, head over to our YouTube Channel or Wire Rope Clip page for more videos and information.
If you would prefer simple text and picture explanations of the information, keep reading.
If you have any questions, please contact our team using the link at the end of the article. We look forward to helping you get your next rigging project started.
If you are looking to form an eye in your wire rope or needing to join two cables together with a lap splice, below you will find information on how to make that connection using wire rope clips.
Terminology
A good foundation for installing these clips properly is knowing the terminology.
The parts of the clip are: the saddle, sometimes called the base or body, u-bolt, and nuts.
Live End
The live end of the cable is the longer portion of the cable that extends to the other connection point. It will be holding the load.
Dead End
The dead end is the short portion that is turned back just so the wire rope clips have something else to grab.
Termination
When the clips are used to make an eye or an end on the cable, it is called a termination.
Assembly
The entire group of components is called an assembly.
Turnback
Turnback is the length of the cable from the base of the eye to the end of the dead end.
“Never Saddle a Dead Horse”
It means to never apply the saddle of the clip to the dead end of the rope.
Materials Needed
A tape measure, seizing tape, a torque wrench, reference information , and the proper size clips for your cable
On our wire rope clip page, you will find reference information, such as, the number of clips required for each termination, the amount of torque to apply to the nuts, and the turnback length.
Prepping for Assembly
Cut off any unraveled or kinked portion of the cable. It is best to seize the cable with tape before cutting to keep the end tight. If you don’t need to cut the cable, be sure to wrap it tightly to keep the structure of the cable in its intended form.
For larger cable, soft wire may be a better choice to hold the cable end together.
Measuring Turnback
Turnback is the length of the cable from the base of the eye to the end of the dead end.
First, measure and mark the turnback length specified in your reference material.
Next, determine how large the eye in your cable will be and mark the live end of the cable where the turnback mark is.
Lastly, mark the live end where the dead-end ends.
“Never Saddle a Dead Horse” is a common phrase to help people remember the proper orientation to apply the clip. It means to never apply the saddle of the clip to the dead end of the rope.
Line up your markings and apply the first clip to the assembly.
Space the wire rope clip one saddle length from the end of the dead end.
Tighten and torque the nuts being sure they are clean, dry, and free from lubrication.
Alternate between the nuts to ensure even pressure. The use of a torque wrench will help to achieve the recommended torque required for holding the load.
Be careful not to over-tighten the nuts as it can permanently kink the wire rope and lead to premature failure.
Apply the second clip to the assembly, remembering to put the saddle on the live end.
Push it snug up against the thimble. If you aren’t using a thimble push it up to the lines you’ve marked earlier.
Hand tighten the nuts, remembering to alternate between the nuts for even pressure.
If your assembly requires 3 or more clips, space them evenly between the first two clips you applied, remembering to never saddle a dead horse and to never alternate the clip orientation.
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