We have an enclosed trailer that was modified to haul classic cars. The rear ramp, modified with steel and 3/4 plywood, weighing about 800 lbs., is raised and lowered by a 2500 lb. winch. 5/16 cable runs over a 2" pulley suspended at the ceiling, just inside the door. After only about 20 open/close cycles, at a point EXACTLY 10 inches up from the thimble where cable attaches to the ramp, the "core" stand of the cable begins to protrude about a 1/2 inch. I tried steel, stainless, and galvanized; always happens in the same spot, same time frame! Any ideas why? I've cut 16" off the end, replace thimble and clamps, and it happens again! View answer
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