[TowerTalk] Wire Rope - Hy-Gain HG70-HD Crank Up

[wn0x at earthlink.net]

Thanks Mike!

I had planned on replacing the cable myself.  Swaging tools and aluminum ferrels for 1/4" cable are easy to come by locally.  As I replace the old cable I will snake the new stuff right behind it to make sure I have things set up properly, paying close attention to the drawing in the manual.

I am relieved not to have to work with the 3/8 inch cable.  There is no one locally that has a swaging tool large enough, and the existing 3/8" cable and clamps don't fit very well in the space between the sections.  

As far as the pulleys...  A local machine shop provided the replacement bearings which were an exact match for three of the pulleys.

The only problem will be a pully in which the bearing completly disintegrated.  I will attempt to drill the pulley out to 7/8" of an inch and replace it with a 7/8" inch to 1/2" bearing, but will have to grind the outside of the bearing down to the width of the pulley.

I called US tower to see if they had 3" pulleys they could sell me.  They have a 3 1/2" by  5/8" pulley with 1/2 inch center for $93.00.  Ouch.

I will let you know how things work out.

Rich





-----Original Message-----
>From: mryan001 <mryan001 at tampabay.rr.com>
>Sent: Jun 20, 2006 10:50 PM
>To: wn0x at earthlink.net
>Subject: RE: [TowerTalk] Wire Rope - Hy-Gain HG70-HD Crank Up
>
>Rich, I just did my tower and the 3/16" for the top section and the 1/4" for
>the other sections is correct. Very important point to be aware of is the
>lengths. If you want the name of the company in Penn that did mine and used
>nicopress fittings on the end I will look it up for you.  My good friend
>Lynn, K3KYT had them done for me and shipped them down to me. They were
>beautiful. Be VERY carefull when lacing the new ones through the tower, over
>the pulleys and to their anchoring positions.  Make a diagram even if you
>have 3 guys watching you!  Any mistake and you will have a real problems.
>Also you better take a LONG look at the pulleys.  I replaced the sheaves
>with some spares I had but also replaced the totally worn out bronze
>bushings within a couple more.  You should look around for some replacments
>if there is ANY doubt that the pulleys are going to be good.  HyGain / MJF
>is not going to have them and PLEASE let me know who you find with a
>genuinely suitable replacement.  The originals are 3" aluminum. Everyone
>said to look into McMaster Carr but they could not help. The best bet in the
>short term is to rebuild the old ones BUT...you and I need to find someone
>who can make a good replacement. The machine shop idea is a good one if they
>are willing to fool with them. They can center drill the old pulley and
>simply make the correct center bearing to press in.  Again, I would be very
>appreciative of any news of replacements.  Is this tower up or are you
>rebuilding a tower to put up as a new installation?  -Mike
>
>-----Original Message-----
>From: towertalk-bounces at contesting.com
>[mailto:towertalk-bounces at contesting.com]On Behalf Of wn0x at earthlink.net
>Sent: Tuesday, June 20, 2006 9:47 PM
>To: towertalk at contesting.com
>Subject: [TowerTalk] Wire Rope - Hy-Gain HG70-HD Crank Up
>
>
>I am rebuilding a well used HG-70HD.  At some point in its life the cables
>were replaced.  It now has 3/8 inch wire rope for the lower sections and 1/4
>inch for the upper sections.  In both cases wire clamps were used instead of
>the crimped fittings.
>
>According to the manual, the lower section orginally had 3/16" wire rope,
>and the upper section 1/4" wire rope.  I am concerned for the accuracy as
>the manual has "HG-54HD" in places where it should have HG-70HD.
>
>Is 3/8" correct?  If someone could actually check their HG-70HD to verify
>this I would appreciate it.
>
>I believe the 3/8" cable is causing problems, especially the very large
>cable clamps.  If it is supposed to have 3/16" cable I would like to use
>that if possible, as it will be easier to find a swaging tool.
>
>Also, one of the pulleys has completely lost its brass bearing, the others
>are very worn.  Has anyone found a source for these pulleys?  I will take
>them to a machine shop tommorrow to see if they can replace them.
>
>Thanks,
>
>
>Rich Beckwith - WN0X
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