How To Install Handrail Cables

• We recommend that newel posts for cable applications be spaced no more than 4 feet
• Keep cable spaced roughly 3” to 3-1/4” a part as there is always some flex with cable and this will make sure you pass code of 4”.
• Cable hardware is technically only needed at the beginning and ending of a run, and the cable can run through the predrilled intermediate posts.
• Gonzato Group recommends ending a cable run at 20-25ft to allow the most strength and tension
• Anything over 20-25ft, it is recommended to use a mid-run tensioner coupling (ET06 w/ETM05DX & ETM05SX) to allow additional tension for the long run of cable. We do not recommend going over 50ft.
• Our cable comes standard in spools of 328ft, in either 4mm, 5mm, or 6mm. Our 5mm (13/64”) is our standard and most popular size due to the rigid offering and having more hardware options available for it.
• Our cable and cable hardware are all 316 marine grade stainless steel, however, please be aware that we offer both 304 interior and 316 exterior grade for our posts, handrail, and components so please make sure to purchase the correct grade material for either your interior or exterior project.
• If drilling your own stainless posts, use drill bit intended for stainless so it doesn’t create burn marks due

CABLE HARDWARE OPTIONS:

OPTIONS THAT REQUIRE CRIMPING (Through-the-post):

• Our ETM05DX male terminal (right hand thread) or our ETM05SX male terminal (left hand thread) to work with our ED06 female dome nut (right hand thread) or ED06SX female dome nut (left hand thread)

• Our ETF05DX female terminal (right hand thread) or our ETF05SX female terminal (left hand thread) to work with our ED07 male rounded head screw (right hand thread) or ED07SX male rounded head screw.

• These 2 options are recommended for our stainless posts; however, if using with wood end posts (through-the-post), make sure to source a heavy duty washer to keep the cable hardware from pulling through the post
  

• If utilizing either of these options on a stair rake, use a sloping washer (EB071 for example) on each outer end post at the start and stop of the run. This helps align the angle. Please refer to our Inox stainless schematics to see the example.
  

DRILLING FOR FLAT & RAKE ANGLES (Through-the-post):

• If deciding to drill “straight” holes in your end posts for a stair rake, you can utilize a few options.
• Use our ED05 (pivotable terminal connector) along with the ED07 and ETM05DX but only in right hand thread offered.
  

• Use our ED06 dome nut right hand thread and ETMT06DX right hand thread (pivotable turnbuckle) with our ETFF05. Available in both right and left hand threads.
  
• If deciding to drill “offset” or holes at an angle for a stair rake, you can utilize a few options.
• Determine the correct angle needing to be drilled by calculating from the rise & run.
• Use our ETM05DX male terminal (right hand thread) or our ETM05SX male terminal (left hand thread) to work with our ED06 female dome nut (right hand thread) or ED06SX female dome nut (left hand thread), and make sure to include the sloping washer (EB071 for example). See Inox stainless cable schematics on website for example.
• Use our ETF05DX female terminal (right hand thread) or our ETF05SX female terminal (left hand thread) to work with our ED07 male rounded head screw (right hand thread) or ED07SX male rounded head screw, and make sure to include the sloping washer (EB071 for example). See Inox stainless cable schematics on website for example.

DRILLING SIZES

• Our ETM05DX, ETM05SX, ETF05DX, ETF05SX for 5mm (13/64”) cable are 7.5mm O.D. (0.295”) with M6 (0.236”) threads.
  

• We recommend for creating your hole sizes that you use:
• ¼” or 17/64” hole for your intermediate posts allowing the cable to run through with minimal gap since the cable size is 13/64” (5mm)
• 19/64” to 8mm (0.315”) hole will allow proper clearance for cable hardware to fit snug within the end posts.
  

WOOD POST OPTIONS:

• When drilling into WOOD newel end posts, we recommend first to pre-drill with either a ¼” or 17/64” bit to allow our ETW05DX or ETW05SX wood lag screw terminals to be properly driven in without accidently cracking the wood post. Can be installed straight or at any angle into wood post.
• 8mm deep socket will allow you to drive the wood lag screw terminal into the wood post properly

• Another option for mounting cable to a wood newel post is utilizing an external pivotable anchor terminal such as our: EMMF06DX/EMMF06SX or EMM05
• Perfect for both straight runs and angles, without having to predrill into the posts

INSTALLATION & TENSION:
Creating tension with our cable comes down to accurately cutting your cable at the correct length.

• Predrill your posts to desired specifications utilizing the #E40580 drilling template…..or Gonzato Group can predrill your posts (drill form required and found on www.gonzatogroup.us)
  
• Mount your posts in place along with the flange canopies to cover the hardware
• Add your cable terminals through your end posts at the start and finish of your run
• Don’t fully tighten the terminals down
• Then measure the length between each end post from where the cable slips in at the farthest point of each cable to the other post doing the same

• From there you will cut your cable at the pre-measured length using the shearing tool (#E40690)
  
• Crimp the inner cable terminals to the cable using the E40685 manual hydraulic crimper (instructions are included with each tool)
• Make sure to use the correct crimper die size that matches the O.D. of the cable terminal (The cable dies are included in the tool kit)

• Recommended to use a left hand terminal on one end and right hand on the other end of run
• Before you begin to thread on the cable crimped terminals to the posts, make sure you begin at the middle of the post and end at both the top and bottom. This allows the tension to be evenly distributed.

• After cable is crimped to terminals, thread the crimped terminals with the end dome nut or rounded head screw depending on which option you preferred. As you’re tightening them on each end of run it will begin to pull the cable fully tight. If cable was measured and cut properly you will feel the cable tension and feel firm. Overly tighten and it will pull too heavily on the posts.

CRIMPLESS TERMINAL (no crimping tool required):
#ETSM300 (#E019760063) – (Offered In Right Hand Thread Only)