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How to attach wire rope to aluminium pergola frame?

YKennedy

Hi all,

We are about to put up a retractable awning under our aluminium framed pergola and are stuck for the best method of attaching the wire rope (3mm) to the aspect of the frame that is flush with the house.

Please see attached photos. We do not want to drill into the frame and there is not way to wrap the wire around the frame at this end. We have done a trial run with nylon rope, which can be wiggled into the holes of the joinery shown. But im not sure if we can do the same with wire rope so thought we would reach out for other ideas.

Many thanks

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EricL

Hello @YKennedy

After carefully studying your pictures, there doesn't appear to be a lot of options in regard to mounting the wire rope without adding either an eye bolt or a timber mounting block which generally involves drilling into the frame. There was a moment where I thought that you could install a timber surround piece on the joist, but your pergola has a clear roof which prevents anything from being wrapped around it.

The only spot that might work is to wrap the wire around the post at the very top and use the bolt head as a form stop to prevent the wire from going down. I suggest using a https://www.bunnings.com.au/taskmaster-3-2mm-copper-swage-12-pack_p0237884 to secure the wire rope. You'll need a https://www.bunnings.com.au/taskmaster-350mm-swaging-tool_p0237888 to crimp the copper swage.

Let me call on our experienced members @Dave-1, @Nailbag, @Remarka6le, @TedBear, @JoeAzza and @DIY4Knuckleheds for their recommendations.

If you need further assistance, please let us know.

Eric

Nailbag

Hi @YKennedy

I can't think of anything that you haven't already tried. Your pretty much limited unless your can permanently fix something to the metal post like these stainless eyelets.

Nailbag

JoeAzza

Hi @YKennedy , I know you don’t want to drill any holes in the frame, what about removing one of the hexagonal bolts , get another bolt the same size as the existing one, then drill through the hexagonal head right through the hex head , then same size as the wire rope, 3mm wire should be ok, pass it through then get some clamps or similar ties to hold it in place, @EricL , should be able to advise on various clamping products, Bunnings have a section where they sell wire and other bits and pieces, doing it this way , you can always re use the original bolt to re install back in place, when you need to.

Dave-1

Good Morning @YKennedy

Ummm not being able to drill into the post makes it a hard call. Could you supply a couple of extra photos of the whole area. When I saw this pop up earlier all the general attachment ideas involve drilling into the posts or rails. If we see more we may be able to come up with some alternatives.

You could mount a post against the house next to the existing post but that only takes care of one side. Will wait for some extra pictures.

Dave

YKennedy

Hi All. Thanks for the ideas so far. Ive added 2 more photos for more perspective.

I also just had a thought. Can you get hollow bolts? If so could swap two out in each side of the beam to thread the wire through.

JacobZ

Hi @YKennedy,

I can't say I'm aware of any hollow screws or bolts that would be suitable, but is there any reason you couldn't back the screws off a bit, then wrap the wire around them a few times before driving them back into place?

These two screws in particular should be able to be backed off, one at a time, then driven back into place without any issues. As the beam is sitting on the bracket, it would still be supported well and if you back one off at a time, driving it back in before backing off the other screw, there shouldn't be a reason for anything to shift.

The only issue I can foresee with this, is that the wire rope might scratch the paint a little bit, but if you're careful, that should be avoidable.

Let me know what you think.

Jacob

Dave-1

Good Morning @YKennedy

Thanks for the extra photos. I like @JacobZ's suggestion about backing off the screws and wrapping wire around them before re-tightening them. You could even go the route of a large flat washer and notch it so it drops down over the screw (using a hacksaw or grinder and a vice)

Tho those screws like like self threading metal screws. So a small pilot hole and then the screw would thread through the metal.

Tek Screws

Dave

Noyade

I'm not sure what weight it (wire) is meant to carry and at what 'exact' position/orientation, but I'm with Jacob - use the TEK (?) screws already available. But I'd be welding a chain link to a Spotlight curtain weight which has been drilled for the returning screw.

Or weld the link to the hex head - reinsert with pliers.

Just pre-lunch thoughts @YKennedy.

Cheers.

YKennedy

I hadn't considered easing out the screws and I think that would be doable for us. We dont have many tools.... definitely no welding tools. Could we use something like this (but heavy duty version) to attach wire. One end to a screw and the other to the wire. It would hopefully prevent scratching on the frame too.

Plan is for 2 wires to carry a retractable shade (approx 4.5 kg). Ive added an example of whay we are aiming for.

Dave-1

Good Afternoon @YKennedy

I would definitely be installing new Tek screws to support the shade curtain.

I have an Ozito battery drill and it seriously will do most jobs. It will definitely drill that steel/aluminium frame (use a small drill for a pilot hole)

Ozito PXC 18V Cordless Drill Driver Kit PXDDK-250C

I have found ozito tools to last and be grunty enough to do the job. Def a tool I would start out with. If you keep an eye out Bunnings do have specials where you might get a few tools together for a cheaper price.

As to the 4.5kg you refer to as in weight it will carry, factor in wind gusts and all of a sudden your bracket will be carrying a lot higher load.

Dave

JacobZ

Hi @YKennedy,

I think that would work well, but you would have to fully remove and then reinsert the screw to do it. As long as you had a drill or impact driver, you shouldn't have any issues. Just make sure you only remove one screw at a time.

Also, while the weight is low, it would still be worth confirming with the builder or manufacturer of your patio that it is fine to support that additional weight just to be on the safe side.

Jacob

Noyade

"definitely no welding tools."

Happy to help. Easy to make - I can post them to you if interested. No cost. Community spirit. Think about it and let me know @YKennedy.

Cheers.

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