Question:

How easy to repair Pop-up camper pulley cable system?

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How easy is to repair a cable pulley system to raise and lower a 1983 (really good condition) Starcraft 24 pop-up tent camper and what do you think the cost would be if we have a professional do it?  We only use it 1-2 times/year since the kids are grown so we don't want to spend too much for repairs at this point.

 Tags: Cable, camper, easy, Popup, pulley, repair, system

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  1. I recently had this problem due to my own ineptitude.  I forgot to unlatch one corner and proceeded to crank the winch to try to raise the top.  I broke the left front cable on my 96 Starcraft pop-up.  Dealers wanted $110 an hour to attempt repair.  First, I raised the top using a 6foot 2x2 and a hydraulic jack, carefully winching a little, the raising the broken corner so it was all level.  Next, I removed the corner post...onlt two 7/16th bolts at the top and 2 screws holding a trim plate.  Since the cable was broken, the corner support lifted right out, not even fastened at the floor.  Next, a trip to HomeDepot for some 1/8th inch cable, collars, and a Swaging tool ( like bolt cutters, but used to crimp sleeves on braided cable).  Total cost was less than $40 and the tool was $28!  My old cable had broken underneath, so I could still see the routing pattern.  I made one loop and fastened it in the post, feed the cable throught the floor and reinstalled the post.  Take care when cutting the cable, it can't be frayed or it will be impossible to feed through the pulleys and collars.  I went underneath and matched the cable length to the remaining cable, then attached the cable end/turnbuckle used to adjust tension.  
    Thse difficult part came when I realized the remaining cable from the winch was wound upon it self....this was the hardest part of the entire repair.  A hydraulic jack and jackstands really helped give some room for this part.  Once untangled, I attached the two cables back together using the turnbuckle.  once re-assembled, adjusting the tension and making sure all four corners raised equally was simple.  One tip that helped was wrapping the cable end with tape and using a cutoff wheel to trim the cable, preventing unravelling.  Having 2 people would speed things up, but it took me the better part of a Saturday to complete this repair, including a trip for supplies.  I'd say expect at least three hours to complete, if you're handy.  Good luck!

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