How Much Winch Line Will Fit on Your Winch?

A winch is a true friend in need. And each part of it should be perfectly matched if you want to build that trust in your equipment. Having confidence in your vehicle and what you bring with you is an essential part of going off-roading.

A winch is irreplaceable for vehicle recovery and lifting. You absolutely must know how to determine what size winch line you need because it is crucial for the winch's performance. This is a Goldilocks solution, you need just the right length, no matter how much you would want to extend it. 

Key Takeaways

• The correct length of the winch line is crucial for optimal performance and safety during vehicle recovery or lifting tasks.
• Utilizing tools like winch extensions or snatch blocks can temporarily extend your winch's reach for specific tasks.
• An overly long cable or rope can create excess tension on the winch drum, diverting power away from the primary function and risking potential jams or tangles.

If you pick a cable or synthetic rope that is too long for you, there will be consequences. The problem is that when the line is too long, it will wrap around the drum in too many loops, creating extra tension. So, the power will go into dealing with that tension instead of doing the job. 

Another thing to look out for is tangles. When there is too much rope, it can get jammed into the mechanism. You have to be extremely careful while pulling with a very long line. 

To avoid damaging your winch, you should find out how to determine the right size. And we're happy to help you with that.

Winch Cable Size Charts by Brand

Warn®

Model	Factory Cable Size	Synthetic Option 1	Synthetic Option 2
ZEON 12	3/8" x 80'	3/8" x 80'	7/16" x 50'
ZEON 10-S, ZEON 10	3/8" x 100'	3/8" x 100'	7/16" x 80'

Ramsey®

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
Patriot 15000	7/16" X 90'	7/16" x 100'	N/A
Patriot 12000, RE12000	3/8" X 125'	3/8" x 125'	7/16" x 100'

Superwinch®

Model	Wire Cable	Basic	Superline®
Husky 10	3/8" X 90'	3/8" x 90'	7/16" x 80'
LP10000	3/8" x 75'	3/8" x 80'	7/16" x 50'

Silver Back Winch Co.

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
8000 SILVER BACK	5/16" X 87'	5/16" x 100'	3/8" x 80'
10000 SILVER BACK	3/8" X 90'	3/8" x 100'	7/16" x 80'

Offroad Power®

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
XP2000	3/16" X 50'	3/16" x 50'	N/A
XP4000	1/4" X 60'	1/4" x 70'	5/16" x 50'

TrailBlazers Gear®

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
Trail X5000	1/4" X 75'	1/4" x 80'	5/16" x 60'
Trail X7000	5/16" X 85'	5/16" x 90'	3/8" x 75'

RuggedTerrain®

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
Rugged 3000	3/16" X 50'	3/16" x 55'	N/A
Rugged 5000	5/16" X 80'	5/16" x 90'	3/8" x 70'

Silver Back Winch Co.

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
8000 SILVER BACK	5/16" X 87'	5/16" x 100'	3/8" x 80'
10000 SILVER BACK	3/8" X 90'	3/8" x 100'	7/16" x 80'

Offroad Power®

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
XP2000	3/16" X 50'	3/16" x 50'	N/A
XP4000	1/4" X 60'	1/4" x 70'	5/16" x 50'
XP6000	5/16" X 75'	5/16" x 85'	3/8" x 70'
XP8000	3/8" X 90'	3/8" x 100'	7/16" x 80'

TrailBlazers Gear®

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
Trail X5000	1/4" X 75'	1/4" x 80'	5/16" x 60'
Trail X7000	5/16" X 85'	5/16" x 90'	3/8" x 75'

RuggedTerrain®

Model	Wire Cable	Synthetic Option 1	Synthetic Option 2
Rugged 3000	3/16" X 50'	3/16" x 55'	N/A
Rugged 5000	5/16" X 80'	5/16" x 90'	3/8" x 70'
Rugged 7000	3/8" X 90'	3/8" x 100'	7/16" x 80'

How to Measure the Winch Drum Diameter?

If you want to measure your winch drum diameter, you should first disconnect it from the power supply and then unwind or entirely remove the cable attached to it. You cannot measure the diameter with the cable still wrapped around the drum. 

I suggest using a caliper instead of a ruler for your accuracy and to make it easier. Measure the drum from edge to edge. 

How to Determine the Cable Wrapping Diameter?

You should start by measuring the empty drum diameter and then proceed to measure the cable's diameter. Remember that each cable layer added to the drum increases the cable wrapping diameter. 

For the first cable layer on the drum, the wrapping diameter equals the drum diameter plus one cable diameter.  And for each new layer, you should add another cable diameter to the formula. This method gives you a close estimate if you don't have the exact specifications.

5 Steps to Measure the Winch Rope Length

Measuring a winch rope's length can be a little tiresome, but it's a simple process. It is as simple as you can imagine, but there are also a few nuances. For example, if you are measuring a synthetic rope, you should do it when it's dry and clean because moisture can make the rope expand and create discrepancies.

So here is a quick guide to measuring the wich line length: 

1. First of all, you should disconnect it from the power supply. If you have a metal cord, then you should put on gloves for your safety. 
2. Now, you should begin to unwind the rope from the drum. It's much easier to do with a little tension to prevent tangling. You can measure it in sections if it doesn't fit. Just figure out how you want to mark those sections.
3. After that, you can take a long measuring tape and measure from the drum to the very end or a hook. 
4. Once you are done, carefully rewind the rope back onto the drum and reconnect the power supply. Remember to go slowly and carefully to avoid jamming. 

Winch Cable and Synthetic Rope Length Formula

If you really enjoy math, this method is for you. Here is a special formula that can help you select the appropriate length of winch cable for the drum. That it is what it is: an estimation. And manufacturer's specs are always more valuable than that.

How To Add More Cable Length?

Found out that the estimated length is not enough? Don’t worry, you can actually adjust for some extra rope length.

There are plenty of small tweaks you can do to fit more cable length. Like switching to a thinner cable or rope or using winch extensions. Just be careful with the second method, it's better if you remove them after you finish the task. 

You can also upgrade the drum to handle more cable if you can find a compatible placement. Or you could get a secondary winch for backup.