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Old 01-19-2014, 08:18 PM   #1
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Zeon cable to synthetic swap

Just out of curiosity, has anyone changed out wire for synthetic rope if the winch came with wire in the first place? It have a Zeon 8 and bought it with cable. I'd like to swap the cable for synthetic rope (the Warn 3/8 100' flavor). Is there a drum difference or anything? I know I will need a polished hawse fairlead to replace the roller.

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Old 01-19-2014, 08:42 PM   #2
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Just did this on my Zeon with Warn 3/8 100' line. The install is straight froward and easy looking on paper. Real life was a little different. Taking the steel cable off was easy. Installing the synthetic Warn line was not. The problem I ran into was the attachment loop was to large to fit through the built in hole on the Zeon drum. The method shown in the instructions using the provided zip tie to pull the line through the drum hole was laughable and was like attempting to put an oversized square peg in a small round hole. The 3/8 line and loop are just to large to fit through. I had to use another method which was more cave man like and involved a mallet.

Once I did manage to get the loop through the drum hole, then came reinstalling the metal locking wedge. This too required a mallet to get it in correctly. After that it was easy to spool the line on.

I would recommend having a friend help because in the real world while installing Warn 3/8 line at home will require three hands.

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Old 01-19-2014, 10:26 PM   #3
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Thanks for the info. I have read people using hangers to get the thing through the drum. I can't wait. Nevertheless, thanks for the info so I can be sure the synthetic line fits. Much appreciated!
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Old 01-19-2014, 11:08 PM   #4
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If you invite a 3rd hand you might want to stock some beer. Just sayin'.
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Old 01-20-2014, 11:35 PM   #5
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Quote:
Originally Posted by Hivedr View Post
Just did this on my Zeon with Warn 3/8 100' line. The install is straight froward and easy looking on paper. Real life was a little different. Taking the steel cable off was easy. Installing the synthetic Warn line was not. The problem I ran into was the attachment loop was to large to fit through the built in hole on the Zeon drum. The method shown in the instructions using the provided zip tie to pull the line through the drum hole was laughable and was like attempting to put an oversized square peg in a small round hole. The 3/8 line and loop are just to large to fit through. I had to use another method which was more cave man like and involved a mallet.

Once I did manage to get the loop through the drum hole, then came reinstalling the metal locking wedge. This too required a mallet to get it in correctly. After that it was easy to spool the line on.

I would recommend having a friend help because in the real world while installing Warn 3/8 line at home will require three hands.
^^^ THIS. I swapped my Zeon steel for Spydura and it was crazy stupid. I am pretty sure I damaged the rope trying to squeeze it through that stupid hole in the drum.

Warn needs to take their instructions and go try it themselves. Video and link that to here so we can have a laugh.
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Old 01-21-2014, 01:35 AM   #6
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You really don't have to use a hawse fairlead, just make sure there's no gouges or nicks in the roller fairlead and make sure the rope wont get caught in the rollers during use.

I don't have a warn, but do you really have to go through all that hell to get the rope through the drum? That's not a weight bearing attachment anyway, that's why you always need to have atleast 5 wraps of rope left on the drum before winching.
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Old 01-21-2014, 10:06 AM   #7
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Installing the synthetic Warn line was not. The problem I ran into was the attachment loop was to large to fit through the built in hole on the Zeon drum. The method shown in the instructions using the provided zip tie to pull the line through the drum hole was laughable and was like attempting to put an oversized square peg in a small round hole.
I spray lubed the end of the line and use weed eater/whacker line to pull it through.

Worked great. Good luck.
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Old 01-21-2014, 10:47 AM   #8
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just did this yesterday and holy hell was that a pain in the ass.. busted a dozen zip ties before throwing some vaseline on the end and getting it through. I had a neighbor help out.. it does make it easier to have help.

and +1 to having warn show the "real" install...
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Old 01-21-2014, 11:12 AM   #9
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I went to a friends garage and tied a piece of rope around an inflated 18-wheeler tire/rim. Then pulled it in with the winch as a means of putting tension on the synthetic line. Worked perfect!
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Old 01-21-2014, 12:34 PM   #10
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You really don't have to use a hawse fairlead, just make sure there's no gouges or nicks in the roller fairlead and make sure the rope wont get caught in the rollers during use.
Not trying to pick a fight over what fairlead to use but I would suggest a hawse just for this reason. I've seen a synth line get cut up in the edges of the roller by being pinched in during strees at an angle. Unless you can guarantee you will not be at an angle that puts your line up against the edges of the roller I wouldn't use one.

The hawse is designed to allow the synth line to slide at any angle.

Enjoy the new line!
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Old 01-21-2014, 07:50 PM   #11
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^^^ THIS. I swapped my Zeon steel for Spydura and it was crazy stupid. I am pretty sure I damaged the rope trying to squeeze it through that stupid hole in the drum.

Warn needs to take their instructions and go try it themselves. Video and link that to here so we can have a laugh.
yeah it was an arse pain to spool the line on my Zeon... I sprayed the crap out of the hole and the end of the rope with silicone spray, eventually I got a thick enough zip tie and a pry bar and I pulled it through.

as others said, definitely have a buddy around. it's more than a one man job...

and x100 on the hawse fairlead. you'll ruin your line with the steel cable rollers.

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Old 01-22-2014, 12:21 PM   #12
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Old 01-23-2014, 08:57 PM   #13
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Well, I ordered the synthetic line tonight so we'll see how it goes. Thanks for all the helpful tips!
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Old 01-23-2014, 09:03 PM   #14
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about 2 feet of 550 cord and hook, with a little silicone spray you'll be good to go. good luck!
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Old 08-27-2014, 07:19 AM   #15
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Helpful thread. Thanks. Living in NorthEast, I'm on the fence with Steel Vs Synthetic. I want to be able to use regularly in snow and I park outside. That said, I also don't want rust.

I may go with the steel and then upgrade if I run into issues over the winter.

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