Hand Winch Wire Rope Assemblies for OEMs

Posted by David Karbin | Tue, Feb 20, 2018 @ 09:13 AM | 0 Comments

hand winch wire rope assemblies-1.jpg

Lexco Cable is the Leading Just-in-Time (JIT) Supplier of Hand Winch Wire Rope Assemblies for OEMs

No matter what type of application calls for a hand winch, they all require a high-quality cable assembly built for durability, longevity, and flexibility. Lead time is critical for OEMs. Lexco’s typical lead time for a wire rope (aircraft cable) assembly is two weeks. Here’s two expedite solutions that you won’t have to pay a break-in fee for.

1) Place a blanket order with specified stock levels.

When you’re ready for a release, we can ship it from stock.

2) Plan a Kanban system blanket order.

We’ll promptly build upon receipt of your empty bin signal.

Blanket orders are a win-win strategy for the OEM and Lexco.


Hand Winch Wire Rope Material Guide

Hot-Dip Galvanized Wire Rope = Quality with Economy

Typical applications for hand winch cable assemblies are found outdoors. Although galvanized-finish wire rope is popular, not all galvanized finishes are the same. In an outdoor environment, an electro-galvanized finish does not protect the wire rope as well as a hot-dip galvanized finish does. If you’re using hand winch wire rope assemblies and are having corrosion issues, we recommend trying Lexco’s hot-dip galvanized wire rope.

Stainless Steel vs. Galvanized Wire Rope

lexco hand winch cable material.png

Galvanized wire rope is a stronger and more economical solution than stainless steel wire rope. If you are a procurement professional and budget is imperative yet the quality is critical, hot-dip galvanized wire rope is the ideal combination of quality and economy.

Determining Your Current Assembly’s Material and Finish

If you’re an OEM that purchases wire rope (aircraft cable) from a source that doesn’t provide material certificates, you might not be 100% positive what material/finish your assembly currently uses. For instance, if a manufacturer puts a stainless steel thimble into the wire rope assembly, the OEM might assume that the wire rope is also stainless steel. This is not necessarily the case. A stainless steel thimble can be used with galvanized wire rope as well.

If you have an assembly and you’re not sure what the material and/or finish is, simply click the link below to download a packing slip and mail it along with your sample. Once received, we’ll hand it off to Lexco Cable’s engineering department to test it. By taking this extra step, Lexco Cable ensures you’re getting an apples-to-apples quote so you can feel confident in your decision making.



Common Wire Rope Diameters for Hand Winch Assemblies

Let’s take a closer look at the most common wire rope diameter for a hand winch:


Part # Diameter Construction Materials Minimum Recommended Drum Diameter Minimum Break Strength Working Load Limit

Weight lbs/ft

 3167GAC 3/16" 7x7 Galv 7 7/8" 3,700 lbs 740 lbs .062
31619GAC 3/16" 7x19 Galv 4 1/2" 4,200 lbs 840 lbs .065


Inside Diameter for 3/16” thimble:

Thimble Size Thimble Material Finish Thimble ID Thimble Part #
3/16" Z.P. Steel 1/2" 316ZPT
3/16" Galv Steel 11/16" 316THDG


Common Hand Winch Cable Assembly Industries and Applications

Everyday, Lexco Cable delivers custom cable assemblies for hand winch applications in multiple industries, such as construction, transportation, and agriculture.

1) Construction & Transportation 

Light Tower Hand Winch - Lexco has vast experience assembling hand winch cables for light towers equipped with a vertical telescoping mast. In the past, we have delivered 3/16 7x19 galvanized-stranded cable assemblies for light towers that require easy vertical adjustments and the ability to rotate 360 degrees.

Fold N’ Go Trailer Hand Winch - Cable assemblies for hand winch applications are also found on the bottom of construction sign trailers. These trailers are used to transport and adjust signs, such as construction arrows, temporary speeds signs, and radar speed signs. For this type of application, a quality custom cable assembly is attached to a connection point and allows for easier deployment.

2) Agriculture / Farming 

Many of our customers come to us for winch cable assemblies found on agriculture equipment, such as a gravity box conveyor used for seeding. Mobile conveyors equipped with a tube-mounted friction disc hand winch cable provides easy vertical adjustments.

3) Tennis Nets 

Tennis nets are often equipped with a wire rope attached to a hand winch. For this purpose, we offer white vinyl wire rope in common diameters of 7x7 and 7x19.

4) Wire Rope Hoists and Cable Puller Winches

Lexco Cable also offers custom wire rope (aircraft cable) for hoists and cable puller winches for durability when it comes to lifting, lowering, moving, and pulling. We have the ability to fabricate a wire rope that can handle heavy working loads, and can provide custom wire rope assembly, equipped with a thimble loop with hook attached.  Hooks are available in carbon and alloy materials and typically include a latch.


Common Hand Winch Cable Fittings



Here is a brief comparison of the four most common cable fittings seen on a winch cable application:

A. Thimble Loop Fitting - Installed on the inside of a cable loop, teardrop-shaped thimbles prevent wire rope fraying and prevent kinking at the bearing point, extending the cable’s longevity.

B. Thimble Loop with Hook - This type of fitting is ideal for hand winch applications that are meant to lift and/or pull heavy loads.

C. Eye-End Fitting - Eye-ends connect to fork ends through clevis pins and improve structural support. They also allow for quick connection and release. An eye-end fitting is highly economical when produced in diameters between 1/32” and 3/16”.

D. Fuse Cut - To prevent the wire ends from fraying, Lexco Cable also offers fuse cutting to electrically cut the wire rope. It’s commonly used for cables with a diameter between 1/32” to 3/8”. We offer custom length per customer specification.

E. Button Stop Fitting - Button stops provide a bearing point for anchoring the assembly to prevent the cable from fraying. A button stop can also act as a stopping mechanism.


Lexco Cable is the leading JIT OEM supplier of custom winch cable assemblies. We deliver custom, quality hand winch cable assemblies with a fast turnaround.

Contact us today for a quote.

Need more information?

Download our 7x7 and 7x19 spec sheet.


Select the Most Well-Suited Materials for your Applications with Lexco's Glossaries

Posted by David Karbin | Thu, Aug 24, 2017 @ 11:11 AM | 0 Comments

When shopping for products you’ve never worked with before, it’s important to familiarize yourself with relevant industry terms in order to ensure you select the best solutions for your specific project.

This is particularly important when choosing wire rope products; it’s critical to have a solid understanding of the industry’s vast terminology. To help you understand important terms and learn more about the various wire rope products available, Lexco Cable has put together six helpful wire rope glossaries, which we created specifically for our customers as well as engineers who wish to find the best possible materials for their project.

Below is a preview of all six glossaries, highlighting the kind of terminology you'll learn about in each glossary, each of which contains images of every product. Thus, if you're a visual person, this will be an especially useful resource for you. Take a look:

Wire Rope Products Glossary

wire-rope-glossary-1-thumbnail-1.pngWire rope products are used in a wide range of environments, applications, and industries. At Lexco, we help guide clients toward the solutions best suited to their unique needs.

There are many unique types of wire rope available, such as:

  • PVC/Vinyl Coated Cable — PVC/vinyl-coated wire rope products are jacketed in a polyvinyl chloride (PVC) coating. The terms "PVC" and "vinyl" are used to refer to the same material.
  • Stainless Steel and Galvanized Aircraft Cable (7x7, 7x19) — “Aircraft cable” refers to any cable that meets commercial (RR-W-410, ASTM A1023) or military (MIL-DTL-83420) specifications for use in aircraft applications. “7×7” and “7×19” are two examples of core constructions. While commercial-grade cable can be made either domestically or abroad, military-spec cable — the only acceptable cable type for critical aerospace applications — is always stranded and closed in the United States.
  • Compacted/Swaged Wire Rope — Compacted/swaged wire rope features flattened strands, allowing for higher breaking strength and abrasion resistance. These products are commonly used in the logging industry.

Wire Rope Fittings Glossary

wire-rope-fitting-glossary-2-thumbnail-1.pngWire rope fittings — end fittings for wire rope assemblies — are used either to close an assembly or to attach it to another product, such as a support riser. There are many types of wire rope fittings available, some of which include:

  • Button Stops — Button stops are small cylinders with inside diameters wide enough to accommodate a single wire rope. Typically crimped at the end of a cable (although they can also be crimped at an intermediate point), button stops are often used as a stopping mechanism on an assembly. While aluminum and copper button stops can be crimped with a hand tool, stainless and carbon steel stops require machine swaging.
  • Thimbles — Thimbles are teardrop-shaped stamped parts that are installed on the inside of a loop at the end of a wire rope assembly. They distribute the load carried by an assembly throughout the bearing point to prevent fraying and kinking.
  • Kwik-Grips — Kwik-Grips are wire rope fittings designed to attach to a suspended object, such as lighting, signs, or display monitors. Easy to install and adjust, these fittings are usually used with 1/16 to ⅛-inch cable diameters.

Wire Rope Hardware and Tools Glossary

hardware-glossary-3-thumbnail.jpgWire rope assemblies sometimes require specialty hardware that does not strictly qualify as a “fitting.” Occasionally, specialty tools are needed for the use and installation of such hardware, which may include:

  • Wire Rope Clips — Usually used for forming loops, a wire rope clip is comprised of a U-bolt, a saddle, and hex nuts. The nuts can be easily tightened with a wrench, making these clips ideal for field installations.
  • Turnbuckles — A turnbuckle attaches to a support structure via an eye, hook, or jaw end. Featuring an externally threaded end that can be mated with an internally threaded wire rope fitting, turnbuckles allow for wire rope or threaded rod assembly length adjustments. The turnbuckle body has a left-hand thread on one side and a right-hand thread on the other.
  • Quick Links — Similar in form to a carabiner, a quick link is a fast-connecting, load-bearing hardware piece most commonly used to connect one or more wire rope assemblies. Available in zinc-plated and stainless steel, quick links allow for fast, easy installation. Typically used in rectangular form, quick links are also available in wide-jaw, pear-shape, delta-shape, and square styles.

Architectural Cable Railings

3d-cover-architectural-glossary-1.pngLexco's deep selection of cable railing fittings allows you to find both the appearance and the function to satisfy your project needs.

  • Stainless Steel Cable Railing 1 x 19 Strand — Typical stainless steel cable railing is 1 × 19 construction. 1 × 19 stainless has minimal stretch, ideal for tensioning. It appears clean and shiny in comparison to other constructions and materials. The most popular diameters are 1/8”, 3/16” and 1/4”.
  • Threaded Terminals — A threaded terminal has external thread on one side and a blind hole for the cable on the other side. It is crimped or swaged onto the cable, then fastened to the end post with a hex nut and capped with an acorn nut. It can be installed at one end or both ends of an assembly.
  • Receiver — A receiver has internal thread and a head, which is used as a bearing point with end posts. Receivers are used in tandem with threaded terminals; the receiver design hides the threaded terminal’s external thread for a more architectural appearance compared to just using a threaded terminal with nuts.

Push-Pull Controls

3d-cover-Push-Pull-glossary.jpgSome conduit assemblies are designed for the inner-cable to be pulled. In this type of control the inner-cable is returned to resting position either manually or with spring assistance.

  • Boots/Bellows — The inner cable goes through the hole on the body of the wire stop and the inner screw gets fitted into place. Fitting is designed to be field installed on one side of a pull control.
  • Equalizer — A rubber, accordion-like fitting. It can provide additional protection of dust, dirt, or moisture from contacting inner cable assembly. It would be mounted between the conduit and cable end fitting. 
  • Clevis — An adapter plate that allows you to connect three push-pull controls together. Two legs from one side, one leg from the opposite side.

Bungee Cords

3d-cover-bungee-glossary-1.jpgLexco fabricates bungee cord assemblies and distributes bungee cord and related materials in bulk. Warning: We do not sell bungee cords for critical load applications such as bungee jumping.

  • Bungee Hooks — Bungee hooks are the most common bungee cord end fittings. The typical hook is metal with a black PVC cover, but Lexco can also supply hooks made from steel and stainless steel.
  • Single & Double Crimp — A solid steel wire is crimped onto the cord. Usually, the cord is folded back before crimping to create additional surface area for the termination. Single crimp means one revolution of wire is crimped around the cord, while double crimp means two revolutions of wire are crimped around the cord.
  • Tarp Straps — Normally used to tie down tarps on flatbed trucks, this option is heavier duty than a bungee cord. It’s a molded strap that has less elasticity. Lexco can provide the rubber in two materials: natural rubber and EPDM. These straps come in specific lengths that are pre-molded, and an ‘S’ hook is attached at both ends.

Learn More

As an industry-leading fabricator of wire rope assemblies and value-added wire rope products — including wire rope fittings, hardware, and tools — Lexco Cable can work with wire rope from 1/32 to 1 inch in diameter, bare plastic or PVC/vinyl jacketed. We can fulfill orders of any volume, from 1 piece to 1,000,000+ pieces, as well as orders of wire rope reels, coils, or cuts. Providing a wide range of custom wire rope assembly fabrication services, we’re proud to offer our clients reliable, long-lasting solutions.

To learn more about our wire rope products, fittings, and hardware, download our free, comprehensive Wire Rope Product Glossary, Wire Rope Fittings Glossary, Wire Rope Hardware & Tools Glossary, Architectural Cable Railings Glossary, Push-Pull Controls Glossary, and Bungee Cords Glossary.


3 Case Study Previews

Posted by David Karbin | Wed, May 24, 2017 @ 09:39 AM | 0 Comments

With spring here and summer fast approaching, the team at Lexco thought it would be a great time to review some of our past outdoor projects — providing cables for an outside shopping complex arbor, working on a living wall featuring vertically planted flowers and plants, and assisting in the creation of a landscaped retaining wall.

Bolingbrook Promenade Arbor

1. Bolingbrook Promenade Architectral Cable Railing.jpgBolingbrook Promenade, a popular outdoor shopping complex in the Chicago suburbs, contracted Nick’s Metal Fabricating of Brookfield, Ill., to design, build, and install a centerpiece arbor. They designed a metal arbor with a wire-trellised top, which initially called for 18 separate wire assemblies to serve as the primary trellising, as well as 36 diagonal assemblies to create a crosshatch pattern.

While we determined that the 36 diagonal assemblies were the best option for this application, we knew that the chosen primary trellising assemblies could be costly and inefficient in terms of installation ease and time. Instead, we recommended a single, long assembly — a less expensive option that was easier to manufacture and required much less installation hardware.

Living Wall Cable Rails

2. Mark's Architectural Cable Railing.jpgFor another project, we were contacted by Mark’s Creative Landscape, a Chicago-based company that designs and installs both residential and commercial landscaping. They had taken on a project for a small commercial client on the North Shore of Chicago and needed help in designing and manufacturing two large-scale living walls.

Living walls are specialty structures used to plant vertical gardens. Premade retail models are available, but none nearly large enough for this application — one wall had to be 12 feet wide, and the other had to be 39 feet wide; both needed to be 14 feet tall. Working closely with the Mark’s Creative Landscape team, we were able to design and manufacture the cable assemblies for the living walls efficiently and cost effectively.

Landscaped Retaining Wall

3. Graham Construction Landscape Retaining Wall.jpgGraham Construction contacted Lexco Cable in regard to a community development project they were working on for the city of Edmonton, in Canada. The development, the Station Pointe subdivision, required a landscaped retaining wall to serve as a separation barrier.

The wall already contained pre-drilled intermediate uprights and required more than 60,000 feet of cable, as well as specific hardware to accommodate the existing components. Meeting all required specifications and successfully working with the preexisting uprights, Lexco was able to deliver the cable in just four weeks.

Learn More

To learn more about these projects and our other past work, view our complete case studies, or contact us today to discuss how Lexco can help with your next project.


Lexco Cable Used in Construction of Suspension Bridge

Posted by David Karbin | Mon, Jun 27, 2016 @ 01:08 PM | 0 Comments

Long Travelled and Treasured

Since the French explorer Samuel de Champlain first set foot in Vermont in 1609, the region has held its reputation as a land of natural beauty and rugged landscapes.  These features have been pondered on by luminaries such as Thoreau and Frost, and enjoyed by visitors from across the globe.

Vermont also features some of the best hiking in the country; it is crisscrossed by over 700 miles of trails and thousands of miles of paths and dirt roads. One of the state's most famous is known as The Long Trail. This aptly named route runs 273 miles from the Canadian border in Quebec to the Massachusetts border in North Adams, where it connects with The Appalachian Trail.

Hikers familiar with The Long Trail can attest to its ruggedness and spectacular vistas as it snakes its way north. It is also the oldest established hiking trail in the United States and was built and is maintained by Vermont’s Green Mountain Club. Construction of the trail began in 1910 and was completed in 1930; its trails and shelters are now maintained by an army of over 1000 volunteers.

Crossing the Winooski River

For over 100 years, the Winooski River crossing in Bolton has been an impingement to full completion of the trail. Crossing the river required the use of a ferry to allow passage from Mansfield to Camel’s Hump or a 3.5 mile road walk.


The idea of a footbridge has been in the works for many years; however, raising the funds needed for the 224 foot span would need contributions from a wide range of sources. Funding for the bridge was finally obtained in mid-2013, and a design was created by the renowned structural bridge engineers at the firm of Vanasse Hangen Brustlin, Inc. of Ferrisburgh, VT.

Construction was then carried out by Kleinhans Construction & Welding of Lebanon, NH.

Proper Use of Cables in a Suspension Bridge

Since this is a suspension bridge, its strength and durability would rely mainly on cabling and cable assemblies. These included cable components for the trusses, the deck, and the cross braces that would support the pedestrian walkway and handrails.

One of the major concerns in a project such as this is the environment. The bridge location is just over 70 miles from the Canadian border, and Vermont winters have a well-earned reputation as being long and harsh, especially in the higher elevations.

What Kleinhans Construction needed in this project was a partner that had broad experience in the fabrication and installation of cable assemblies.  For these reasons, they selected Lexco Cable of Illinois to provide all of the required cable and cable assemblies.

Lexco has over 30 years of experience designing and fabricated high strength cable assemblies for some very demanding industries. Their design expertise can be the difference between a good bridge and a great bridge, and their understanding of assembly and installation of structural elements makes the overall build process much easier.

After being contracted, the Lexco team performed a comprehensive review of the architectural drawings. In their study, they identified a number of clearance issues that would have impeded design functions of various support cable assemblies. Without altering the original design, they were able to develop alternatives that would not affect any aspect of the project.


During Lexco’s design process, they created individual engineering drawings for each of the numerous cable assemblies. Each assembly was unique and varied in length and diameter; in addition, each unit required a special turnbuckle.

 Lexco’s manufacturing operation relies heavily on quality control; all components were checked for dimensional accuracy, and each assembly was load tested to ensure a long trouble free service life.

In a short time, Kleinhans Construction had all the parts and components that they required to quickly build a suspension bridge that would provide safe crossing of the Winooski River for thousands of hikers every year.

Lexco Cable specializes in providing services that go far beyond just fabricating parts; they work closely with customers to obtain a full understanding of specifications, design intent, and what is really expected of the finished product.


Lexco Cable Joins Technology Manufacturing Association

Posted by David Karbin | Wed, Mar 04, 2015 @ 11:24 AM | 0 Comments

Lexco Cable joined the Association of Manufacturing Technology on Nov. 12, enabling us to offer customers unprecedented access to resources for almost any project.

Norridge, Illinois — Feb. 17, 2015 — Lexco Cable, manufactures a custom mechanical custom cable assembly. We distribute wire rope, aircraft cable, coated cable, and related fittings and hardware. We are proud to announce our membership in the Technology & Manufacturing Association (TMA). Through this membership, Lexco Cable can offer customers unparalleled access to resources for almost any project, regardless of level of complexity.

Lexco TMA Membership

With 900+ members in North Eastern Illinois, TMA is a non-profit that brings together leading precision manufacturers and suppliers of precision items. The Association is committed to manufacturers of recognition as the value aggregates producers of goods and services and to create high-quality jobs for all citizens of Illinois. It also promotes a strong sense of mutual support among members and throughout the industry in general. With this, finally, the Association advocates on behalf of the interests of its members to generate growth and offer positive benefits to TMA members and communities in Illinois. Finally, the Association advocates on behalf of the interests of its members to generate growth and offer positive benefits to TMA members and communities. 

"Joining TMA was a natural fit for Lexco," said David Karbin, Product Manager at Lexco Cable. "One of the pillars of our quality policy is 'continuous improvement'." Sometimes, these ideas of improvement come internally, but participating in events of TMA, we open ourselves up to a vast wealth of practical ideas that will help us to speed up the improvements of our company." 

TMA offers a variety of services ranging from media relations to leadership training and education. It also provides access to employee training for new skills, seminars, networking opportunities, and guest speakers.

“Lexco Cable joined TMA and immediately did what most members should do—raise their hands and ask a question,” said Kent Gladish, Senior Marketing and Sales Director at TMA. “TMA connects members to others who have solved that problem. David Karbin’s questions are excellent, challenging, and needed by others. In one case, the TMA Marketing committee will be asked to assist with a comprehensive answer.”

Lexco Cable offers a variety of wire rope, aircraft cable, bungee, fittings and other related services. Visit Lexco's website to learn more about their capabilities.

About Lexco Cable:

Lexco has capacity domestically and abroad. We have a network of providers of coated cable, aircraft cable, wire size micro, bungee, accessories and services related to provide your specific custom assembly of cable or rope. We run vinyl coated cable and plastic coated cable. We have hydraulic presses and automatic wire cutters. We have test capabilities for your test and tensile test requirements related to provide your specific custom assembly of cable or rope.  

Lexco Cable is a family-owned and operated business. It began as a hardware store and Schwinn franchise on the west side of Chicago in the 1950s. We continued as a Schwinn bicycle shop on the city’s north side in the 60s. In the 70s, Lexco began using aircraft cable and making bicycle and retail security cables. During the 1980s and 1990s, industrial applications for cable and wire rope assemblies were developed, and capabilities supporting applications fleshed out. In the 2000s, bungee assemblies, push-pull controls, and their unique elements were developed.

We have been ISO 9001:2008 certified since 2009.

We enjoy the challenges of new applications and welcome your inquiries.


Lexco Cable is Proud to Announce the Winners of Our Photo Contest

Posted by David Karbin | Tue, Feb 24, 2015 @ 09:54 AM | 0 Comments

In November, Lexco Cable held a contest for best photo featuring a Lexco product in the picture.

The rules were quite simple. Each entry had to feature a project integrating any product from Lexco Cable, whether it was a cable assembly with aircraft cable or wire rope hardware and snap hooks.

The goal was to connect with current and past Lexco Cable customers and see how they are using Lexco products in their applications. This call to submit entries went out in the fall and at the end of the year we started reviewing to determine which photographs were the most attractive, fun, and the best examples of Lexco Cable products in action.

There was a large range of photos submitted to the contest. Many of the photos were of very high quality and clearly showed the Lexco Cable product in action.

The applications ranged from marine to canopy support, to mechanical linkage, to architectural.

It was exciting to see how all of these products and projects integrated Lexco’s products with such beautiful photographs.

The Winners

Now, we are pleased to announce the winners of Lexco’s photo contest.

Our first winning photo comes from Blue Water Furnishings with this beautiful architectural cable railing shot:  

Cable Railing from Blue Water

Blue Water Furnishings ( is based in Phoenix, Ariz. They have been a Lexco customer since 2010.

Blue Water Furnishings makes architectural features for homes and businesses in the serene southwest. Lexco is privileged each time we have the pleasure to supply cables to Blue Water Furnishings. The clean lines of stainless cable rails against the backdrop of the desert and beautiful infinity pool (looks like Blue Water lives up to its name!) always make for a visually stunning contrast.

Our second winning photo comes from Jed Smith Construction’s fantastic work, which can be seen in the below architectural railing shot:

Jed Smith Construction cable photo

Jed Smith Construction ( is based in Aquinnah, Mass. Aquinnah is surrounded by the Vineyard Sound and the Nantucket Sound in Dukes County on the U.S. eastern seaboard.

Cable railings built by Jed Smith Construction compliment the architectural style and views of homes built on the Atlantic.

And finally, our third photo winner features cables installed on a speedboat named the "Barefoot Sanger."

Barefoot Sangover

The water skiing boat belongs to Dave Steffes of Saint Paul, Minn. Dave used plastic-coated stainless steel aircraft cable to support an extended height tow pylon for barefoot water skiing. According to Dave, "it's been used several summers now and is still rock solid."

The photo winners will now receive a free digital caliper, a very useful tool for measuring dimensions in applications needing wire rope products.

Winners of the contest also have the option of having their project featured on Lexco Cable’s profile on Houzz, the online architecture, interior design, landscaping, and home improvement network.

Congratulations to our winners! And thank you to everyone who participated. Feel free to continue sending us photos of your wire rope projects.

Submit Your Photo


Download Important Documents from Lexco’s Technical Resource Library

Posted by David Karbin | Mon, Jan 19, 2015 @ 08:06 AM | 0 Comments

Get useful conversion charts, guides, and much more.

Lexco Cable presents our Technical Resource Library, a range of documents related to the wire rope and cable industry. These are offered as references to easily consult when purchasing wire rope, specifying a new project, or checking measurements.

Procurement Guides and Detailed Charts

Technical Resource Library

Our Resource Library is dedicated to helping you at various stages of any wire rope, or cable application. As a result, we have documents such as the Decimal/Metric Chart, side-by-side comparisons of measurements of wire rope and cable diameter in inches and millimeters.

Also available in our Resource Library is the Wire Rope Diameter and Construction Design Guidelines. This chart recommends the minimum bend required to maximize wire rope life and strength for cycling applications. The document includes various wire rope and cable profiles, helping you find the products compatible with your project requirements.

Customers can also find our Push/Pull Replacement Guides. Each of are quick references on replacement cables in a variety of vehicles and applications, including:

  • Tractors
  • Excavators
  • Cabover Engine Trucks
  • Tow Trucks
  • Generators
  • Work Boats

There are nine replacement guides included in our resource library to help you find the right cable for your specific application, including aircraft cable, vinyl coated cable or plastic coated cable just to name a few.

A Range of Comprehensive Wire Rope and Cable Considerations

Additional documents in the Lexco Cable Resource Library include:

Each of these documents is designed for proper procurement, installation, and care of your wire rope and cable products. Most importantly, these documents can be printed out and hung up in the office, letting you easily check them for quick reference.

Click here or the button below to visit our Technical Resource Library and download any of the above listed documents:

Access Our Resource Library

For all additional questions, including any questions on topics not covered in our library, contact us today. We hope these resources are exactly what you are looking for.


Submit Your Photo of a Lexco Product for a Chance to Win

Posted by David Karbin | Thu, Nov 20, 2014 @ 10:38 AM | 0 Comments

Do you own or work with a Lexco Cable product? If you do, then you are eligible to win a prize just by submitting a photo.

All you have to do is snap a quick picture of your Lexco item that has been used in one of your projects or products. As you know, we are one of the largest wire rope manufacturers with our products such as the wire rope, aircraft cable, and the bungee cord!

describe the imageFor example, our products have been used is within the brewing industry. Hops, which give beverages their tangy taste, is grown very similar to grape vines.  Utilizing strings that are tied to a Lexco-produced cable, the growers can keep their hop plants off the ground via the wires, saving it from harmful bacteria and spoilage.

So, now is your chance to become the photographer and capture one of your products in action. If you win, it could become as well-known as the cables that assist the Skycam in its vital Super Bowl work. Who knows? 

The photos can be taken anywhere, whether it’s at the car dealership holding the spare tire into place, or even you playing at a slot machine, where it is in use. The more creative you get, the better!

Here's one idea — capture one of our products by hanging from an anchor of a boat.  In many anchors, the cable used to help raise and lower it is a product of ours. The possibilities are endless!

Once you take your photo, be sure to go to to fill out the form and submit your photo! May the best photo win.

Submit Your Photo

The Beauty of Flaming Hula-Hoops (Accomplished Using Wire Strand)

Posted by David Karbin | Tue, Oct 14, 2014 @ 09:36 AM | 0 Comments

We at Lexco Cable are always excited and amazed to find a new or unique use for many of our cable assemblies.  One customer, Synergy FlowArts came to us to help them supply cable in keeping with safety and integrity requirements of their products.

quick wick resized 600

Synergy FlowArts manufactures products that encourage the growth of this unique art form that combines exercise, performance, and spirituality.  Flow Arts include a wide range of movement styles, forms & rhythms, often incorporating performance props.  Many of these props come in “fire-form” for fire spinning performance. Synergy FlowArts fabricates hoops and other tools such as their Quick Wick for use in firehooping. The Quick Wick is a clamp-on wick for a flame or multiple flames, turning an ordinary hula-hoop into a “firehoop.”  Each of the Quick Wicks clamps onto the circumference of the hoop.

The company has been utilizing Lexco’s wire strand to mount the flame wicks about 5 inches away from the plastic hoop tubing. During the performance, each wick is ignited. Due to the properties of the stainless steel wire strand, the rapid temperature changes that occur when lighting the wicks do not affect the hoop or damage it while under the intensity of the fire. Due to wire strand’s desirable rigidity for this application, 1x19 was supplied. Lexco also provides 1x7 wire strand for this client for whenever greater rigidity is desired.  

With help from our wire strand Synergy FlowArts is able to provide their customers with the safe and reliable performance equipment to make their art extraordinary. Many of their customers are multi-hoop fire spinners and they even have some Vegas style performers. Here at Lexco Cable, we help make that possible with our dependable and diverse selection of wire rope products. You may not find us spinning fire, but we continue to innovate, support and collaborate with clients, helping to create unique products for unique markets.


Consult a Cable Expert

Lexco Cable and Pull Testing for Wire Rope Assemblies

Posted by David Karbin | Mon, Sep 15, 2014 @ 09:24 AM | 0 Comments

Pull testing is an effective means of testing the strength of wire rope assemblies to ensure they meet the specific requirements of the customer’s application. That’s why Lexco Cable offers these services for our customers. We can proof load to a percentage of the break strength or we can perform a fully destructive pull test to determine at what point a cable assembly meets its limits.

Pull Testing in Action

In the video below, you will see a cable construction of 5/8” diameter, 7x7 galvanized wire rope being pull tested to verify the swage sleeve would hold to 100% strength efficiency. When completed, this type of test indicates the break strength of a cable assembly based on a gradual linear pull.

In the test shown in this video, the cable assembly met the nominal break strength required by the customer, exceeding it by more than 10%. While this particular test was done to destruction, there are other tests performed to measure a percentage of that break strength requirement.

Pull testing as shown in this video is a vital part of the quality control process. The machine used is a 55 foot long pull tester, calibrated for testing up to 50,000 lbs against a cable assembly, allowing Lexco to perform extensive tests for our customers, whatever their requirements might be.

Contact Lexco for More Information About Pull Testing

If you need to learn more about pull testing and its benefits, contact the experts of Lexco Cable. We can discuss with you how best to match the break strength requirements of your cable assembly and then perform the necessary testing to ensure this is the case.

Click the button below to fill out a form or call us directly and speak with an expert who can help you with your custom cable assembly, cable assembly pull testing, or general wire rope needs. 

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