In this article, we’re going to dive deep into the installation process of HAAS REVO Thru-post Tensioners. These tensioners are designed to provide a sleek and professional finish to your cable railing system, ensuring both strength and aesthetics. Let’s walk through the steps together!
First things first, you’ll need your marking template to outline where the holes will go on each post. For drilling through-post cable railing fittings, we’ve found that the best technique is to drill halfway through from one side of the post, then finish drilling from the opposite side. This method helps prevent splintering on the exit side of the post. Make sure to mark your posts carefully before you begin drilling.
Once your holes are marked, grab your drill and a 3/8†spade bit. Set your drill to its highest speed setting for clean, precise drilling. Align the tip of the drill bit with the mark on the post, making sure it’s as straight and level as possible. Start drilling until the hole is about halfway through the post. Repeat this process for all the remaining marks on that side, then switch to the other side of the post and repeat the entire process.
After drilling, it’s crucial to clean out any sawdust or debris from the holes to avoid complications later on. Now that your holes are ready, let’s move on to assembling the REVO through-post tensioner.
Your REVO through-post tensioner consists of four main components: the swage stud, which attaches to the cable end; the centering bushing, which slides into the post hole and guides the threaded stud; the 1/4-20 hex nut, which tightens the cable and ensures proper tension; and the end cap, which finishes the assembly for a polished look.
Start by trimming the cable to the correct length for your tensioning fitting. Feed the cable through the appropriate hole in the post and pull it taut from the backside. Mark the cable where it enters the post, then release the tension and use the swage stud to measure the cut mark. Align the stud with the first mark and create a second mark at the indentation line. Cut the cable at the second mark and repeat this process for all the cables in your run.
Slide the wood post protector onto the cable (if applicable), ensuring it’s oriented correctly. Insert the cable into the swage cavity of the stud and secure it tightly. Use a swager to create two swages, rotating the stud 90 degrees between each swage to ensure a strong connection. Thread the stud through the post, followed by the centering bushing, and secure it with the hex nut. Tighten the nut by hand for now.
With all the tensioners installed, it’s time to complete the tensioning process. Begin with the middle cable and work outward, alternating between top and bottom cables to ensure even tension across the run. Use a 7/16†ratcheting wrench and vise-grips to tighten each stud, counting half rotations to maintain consistency. Once all cables are evenly tensioned, use an angle grinder to trim the excess threads of the stud, ensuring they’re flush with the hex nut.
Finally, thread the end caps onto the bushings to complete the installation. With everything in place, your cable railing system is now ready to impress! If you need further guidance, check out our other tutorials on HAAS Stainless REVO Standard and Low-Profile Endstops and HAAS Stainless REVO Lag End Stops.
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