Reproduction of Tow Rope Parts

[jfo137]

Matt,
On eBay you can find “Airborne letdown rope” the description says its 5/8 thick and it looks to be the correct braided cotton. That might be your best bet for rope. I have been told that some of the letdown rope being sold is 3/8 thick which would not be the correct thickness for handcart ropes so....buyer beware. As for the crimps, you might want to make them yourself. I don’t have the original specs but I am sure someone on the G could provide them.

[matt506]

Thanks those were my next questions. So rope is 5/8 thick then the crimps should be 5/8 also I suspect. McMaster car does list both rope and what they call steel "oval"crimps. Should be able just to press them in my press. Thanks I will check the letdown rope also. Matt

[matt506]

Thanks winged I will check on .rope suggestions also. What are the overall lengths of the 5/8 rope? That should do it then. Matt

[jfo137]

I remember seeing a post here that had measurements, dimensions and I want to say they were 5 ft.

[W. Winget]

I think it's called Diamond Braid Rope, are you sure it's 5/8ths and not 5/16's?
5/8's is pretty large (just asking, seems more rare too)
V/R W Winget

[matt506]

Winget, that's what I am asking. 5/8 seems real big but I seen 3/8 and is pretty common in diamond and cotton.

[jfo137]

Let me see if I can find the old post with the dimensions in a photo.

[retro-roco]

Here are the pictures from previous posts that I saved...

[jfo137]

That’s it thanks!!!! If my math skills are correct .6 would = 5/8....ish

[W. Winget]

Ok, talked with a sailing friend (Scoutmaster: Boy Scouts, Sea Scouts) in last night, he offered up they make it for horse lead and bridles as the horses will eat the ropes, they make it in cotton so they won't get sick.
Dig a little further and BAM. (only one source I bothered with, no doubt there are more)
"Solid Braid" cotton.
5/8" 16 mm ( # 2 is 0.625 by the way) sold here
http://products.consolidatedcordage.com ... /item-1114

PRODUCT # DIAMETER SIZE PUT UP(FT) AV. TENSILE Strength APPROX spool WT
SB( )-0580050 5/8 20 500ft spool Exceeds 40Lbs

Or in their catalog: on page 5 (the companies PDF)
http://www.consolidatedcordage.com/pdf/ ... re-new.pdf
Link to main company site:
http://www.consolidatedcordage.com/index.html
View of type of rope.


PS: I imagine the wire is either High Tensile Steel and Heat treated after forming with a joining weld under the leather in the center of the handle. V/R W. Winget

[matt506]

OK thanks guys. Winget awesome on finding rope. Yes these are welded, at least Hayes are. I have leather and my shoe repair guy is going to try to sew the leather tonight, so this may come together. Now to find the crimps in 5/8 and steel. I believe McMaster has these but not sure how they look. Depending on how much I'm charges for the leather sewing it is looking Well under 200 for a set reproduced. Matt

[W. Winget]

Hard to see, but is the steel crimp and open type sleeve that is wrapped then swaged? or a closed tube that is swaged top and bottom to lock the ropes in?
Swages seem to drift toward steel cable applications and are those ugly ovals with two holes, which are fine for that application, but not what your seeking.
I suspect it's 1" long steel tube that is just crushed top and bottom at the same time. Might take a little experimenting to get the sizing correct with some excess rope, but 3/4" or 1" diameter tube may fit the bill there. Making a die to crimp it top and bottom cleanly might be done by drilling two holes in a 1" thick piece of steel stock side by side, then slicing it open on a bandsaw or die cutter yielding 2 halves that can be placed in a vise with the sleeve/rope inserted and squeezed (or an arbor press) (edit: or cut a steel cable two channel swag in half yielding the stamping die set, no drilling needed)
V/R W. Winget
(And I don't even have a cart...shucks. )
$59 at Harbor freight.

[matt506]

Winget, was thinking of rounding off the edges of two drag link sockets and useing them to slowly crush the center together. I'll investigate your idea with tubing but the ones in McMaster catalog look very simular and are listed spacific to use on ropes. The only concern I would have is the issue of the thickness as the aluminum ones are really thick walled. Hopefully these are thin as used for rope and not cable. The even have a warning to not use them for lifting so maybe not very heavy duty. Matt

[W. Winget]

Only reason I mention tubing is if you ever saw the end caps for the flat straps, these are metal cups, which when laid flat and struck with simple hammer blow forming into the tab we see on the end of the strap.
Factory use of a tube and stamping die would have simplified the manufacturing process VS a formed ferrule (possibly)
The use of zinc coated? steel should match up nicely with the original (the intent) use of aluminum would be ok if using them for any real work, but the intent is authenticity, so checking with a magnet would confirm material and looking at the profile of the clasp end should indicate if it was a closed sawged loop or an open "3" shaped/rolled metal /swaged into a closed pinch type fastener

If I was going to do this at my place I would try a few different pieces and see what the results were. You can only make it "correct" once.
W. Winget

[matt506]

OK well here are the handles with raw undies leather. These are hand sewn , not perfect but a start, 15.00 was total and to date for handles, shipping and sewing supplies I am up to 105.00. Add the drop rope for 35.00 which will cover up to 2 sets of ropes this should easily be under 175.00.