There are many websites out there that show how to calculate the thickness of cable and how much weight it could support. But in general, if the length of your zipline is less than 200 feet, you could either use 3/16″ or 1/4″ cable. Both 3/16″ and 1/4″ cable can withstand up to 250 lbs of weight.
In our case, we have few pine trees in our backyard and the distance from the farthest two trees is about 80 feet. I could have used 3/16 cable, but to be on the safe side I bought 1/4″ cable for the zipline. Having stronger cable is a plus since adults would love to try going on a ride as well.
Stretch the cable on the ground and loop around the trees to figure out the total cable length that you need. Using a grinder, cut the cable to the correct length. Make sure to cut the cable slightly longer, just in case. You could always cut it shorter once everything is installed.
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Remove any branches that might be in the way. You don’t want kids to be scratched by the branches while riding the zipline. When wrapping the cable around the tree, it’s a good idea to place protective blocks under the cable so that cable is not touching the tree. These blocks will protect the tree from damage that stretched cable might cause. Depending on the size of your tree, you might need a different amount of blocks then what I installed. The diameter of both trees in our backyard is 20″, so installing three blocks per tree worked out well.
Take 2×4, preferably treaded wood, and cut six pieces to 10″ in length. If you have a bigger tree you might need to add more blocks. Then rotate the blade of your skill saw to 45″ degrees and cut a 1/2″ deep groove in the middle, just wide enough for the cable to be placed in. Do that on all six protection blocks.
Before attaching the blocks to the tree you need to figure out the height of your zipline. The zipline needs to have a slope in one direction. For slopes that are 6% (6 feet drop per 100 feet of distance), you will need to have a bungee brake. For slopes that are 3% or less (3 feet drop per 100 feet of distance), the bungee brake is not required. Do not exceed a 6% riding slope. High-speed collision with end point may cause injury or death.
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