Winch Cable and Synthetic Rope

Wire rope versus synthetic rope

Wire rope is the traditional choice. It is tough against abrasion and heat and generally costs less, but it is heavy, can develop sharp burrs and kinks, and stores energy that can be dangerous if it breaks. Synthetic rope is made of high-strength fibers, is far lighter, floats, and does not coil as violently if it snaps. It needs more care, since it can be damaged by heat, rough edges, dirt and ultraviolet light.

Match the line to your winch

The rope must suit the winch drum. Check the rope diameter, the length the drum can hold and the breaking strength. A common guideline is that the line's rated breaking strength should be well above the winch's rated line pull, and following the winch manufacturer's recommendation is best. Replacing a line with the wrong diameter can lead to poor spooling or lower capacity. Also check the end fittings, such as a hook, thimble or loop, and the fairlead type, since synthetic rope typically needs a smooth aluminum fairlead and wire rope uses a roller fairlead.

What to compare

• Diameter and length
• Rated breaking strength
• Cover or sleeve, which protects synthetic rope from abrasion
• End termination and whether a hook is included
• Whether the product is a full replacement or only a section

Safe use and care

Always wear leather gloves, and never grip a wire rope with a bare hand. Keep people clear of the line, and use a recovery damper or a heavy blanket draped over the line. Never let a winch line run past the last few wraps on the drum. Inspect the rope before each trip, and replace it if you find broken strands, flat spots, melted fibers or stiff sections. Rinse synthetic rope and let it dry, and re-spool it under tension so the layers do not bury each other.

Compatibility

Drum sizes differ by winch model. Confirm fitment for your winch model, check the manufacturer's specifications for rope diameter and length, and use only components rated for your recovery loads. Pair the line with a properly rated hook, shackles and a tree trunk protector so the rest of the recovery chain is as strong as the line itself.

Spooling and storage

How the line is wound on the drum matters. When respooling, keep light tension on the line, such as by driving slowly while winching in, and lay the wraps tightly and evenly side by side. Loose, crossed wraps can pull into the lower layers under load and jam or damage the line. Avoid pulling at extreme angles, since the rope can pile up at one end of the drum. Store the line clean and dry, with the hook secured so it does not hang loose. Replace the hook and other end hardware if it is bent, cracked or rusted. For synthetic rope, use a protective sleeve where the line may touch rocks, and keep it away from engine and exhaust heat.

Mark the rated capacity of the line in your records and keep any tag or paperwork that came with it. If you ever shorten, splice or repair a line, follow the manufacturer's guidance, since improper repairs can lower its strength.