[TowerTalk] Please critique my plan for installing this tower and lighti

[K7LXC at aol.com]

>  1.  Tower - The tower is a 20 year old used 73' US  Tower (Model 
HDX-572) 
in fairly good condition.  Before starting the  installation, I will pull 
it apart, replace the pulley sheaves and wire  ropes as well as wire 
brushing and spraying on a coat of high-zinc content  cold galvanizing 
paint.  (It has a prop pitch motor for a  rotator).
 
    Congratulations on your project. Should work  great when you're done.  
 
    The question is "Is it worth the effort to  replace the sheaves, cables 
and galvanizing?"
 
    I would be skeptical of replacing the sheaves and  cables. I have 
worked on dozens of crank-ups over the years and I have yet to  see one that 
required the work you're suggesting. 
 
    There are 3 reasons to replace the cables  (these are all covered in my 
tower book): 1) Excessive broken strands. Industry  specs say you can have 
6 broken strands before replacement is recommended. 2)  Excessive rust. 
Cancerous rust - not surface rust. 3) Damage. This would be  kinks or flat spots 
in the cable. 
 
    If you don't meet this criteria, then it's  more psychological than 
real benefit.
 
    As far as using cold galvanizing paint, it's  a band-aid but again 
offers more psychological benefit. Hot dipped galvanizing  will last 20-30 years 
or more while the cold galv spray is only good for several  years.
 
    UST uses sealed bearings pressed into their  sheaves. I have yet to run 
into one that was fatally overworked to the extent  that it needed 
replacing. In the old days the sheaves just turned on bushings  that did eventually 
develop problems. Remember the pulleys are only worked  occasionally and at 
slow speeds so it'd take a lot of work to wear one out. 
 
    Please don't let me discourage you from this  project but I just wanted 
to offer a different perspective for the amount of  work you're proposing.  
If you're looking for a project, then knock  yourself out. 
 
    In any case you'll have fun in the  end so whatever you do, it'll be 
worth it. 
 
Cheers,
Steve     K7LXC
TOWER TECH -
Professional tower services for amateurs