Cable Rail Tensioner Kit for Vinyl or Composite Post Sleeves

• Overview
• Installation

• Cable Rail Designed for Use with Post Sleeves

  Each Cable Bullet tensioner kit includes the universal fittings necessary to set one end of a single cable run. Each end is interchangeable and can be tensioned separately. The ability to tension each run on the post interior eliminates the need to drill through the post and is also what makes this system perfect for sleeved posts. Cable runs don't have to be staggered or off-set around corners, the same hardware can be used on level or angled rail sections, and all tension is transferred to the center post and off the sleeve.

  Each Bullet (or tensioner) includes a pre-fitted EPDM rubber o-ring and a steel ring designed to cap the slightly larger hole through the post sleeve. It also protects the sleeve from the cutting edge on the backside of the tensioner and has a clean, finished look once installed.

  To guarantee long-lasting beauty and durability, all Cable Bullet hardware is made from high-quality 316 marine-grade stainless steel and manufactured exclusively in the U.S.A.

• Installation Instructions

  General Guidelines

  End posts should be spaced no more than 20 feet apart and must be braced top and bottom to support the combined tension of every cable run within a section (150–200# per run). To keep cable deflection at a minimum, add intermediate (pass-through) cable support posts every 3-½ to 4 feet. Cable runs should be spaced 3" apart.

  Preparing Your Posts

  Shim your post sleeve so it makes even contact with the face of the post you'll be installing your cable rail hardware on. Mark all your holes on the post sleeve. Drill a 5/8-inch hole through just the sleeve for only the very top and bottom endpoints. For your Bullets (or tensioners), drill a 9/16-inch hole centered on your sleeve hole. The appropriate depth will vary based on the size of the post, your sleeve, and the tensioner size you've selected. Set your top and bottom Bullets first to fasten the sleeve to the post, then drill and set the remaining tensioners. The rubber o-ring and steel cover ring will help seal and cover the sleeve hole for a clean, finished look.

  Installing Cable Bullet Tensioners

  The Cable Bullet InstallationKit (sold separately) is required to set all tensioners, securely fasten cable ends, and tension each section. It includes Bullet and set-screw drivers as well as amodified YYQ-300 16-ton manual hydraulic crimper that's been refitted with a custom hexagonal die. The hexagonal crimp along the full length of the crimp sleeve is necessary to securely fasten each cable end under tension. Because crimp sleeves are made of stainless steel they are extremely difficult to crimp using manual cable crimpers.

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  Click here to download the full instruction sheet.

What's included in a kit?

Each cable rail tensioner kit includes all the fittings necessary to anchor and tension a single cable end:
(1) Cable Bullet for wood posts, (1) steel ring, (1) rubber o-ring, (1) crimp sleeve, (1) lobed washer, (1) #10-32 x 1/4" half dog socket set screw.

Choosing the correct tensioner for your sleeve size

Our sleeved wood post cable rail hardware is available in three sizes; a standard 1-1/2-inch long tensioner, a 1-7/8-inch XL, and the 2-3/4-inch XXL version. Order the size that's appropriate for your vinyl or composite sleeve by measuring the distance from the face of the sleeve to the center post. The longer shank on both the XL and XXL tensioners is designed to pass through the cavity in larger sleeves and make full contact with the post. The standard 1-1/2-inch long tensioner should only be used with thinner sleeves that are flush to the post itself.

What cable should I use?

All Cable Bullet cable railing kits were designed exclusively for use with 5/32-inch diameter cable. If your project includes sloped or angled rail sections, we highly recommend using 7x7 braid cable. The additional flexibility of the 7x7 cable braid allows for cleaner lines and tighter angles between staggered or angled posts.

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