Birtley Cones and Cables Replacement
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How Do I Replace Birtley Cones and Cables?
Frayed or snapped Birtley lift cables cause the door to drop or sag on one side and are one of the most common Birtley door repairs. Cables and cones are inexpensive and straightforward to replace. This guide covers how to identify the correct parts and the full replacement process for Birtley canopy door cables and cones
Birtley cable and cone system
Birtley canopy doors use a lift cable on each side of the door. The cable is wound around a cone (cable drum) mounted on the spring shaft end. As the spring unwinds when the door is opened, it rotates the shaft and cones, winding up the cables and lifting the door. When a cable frays or snaps, the door loses support on that side and drops.
Identifying the correct cable and cone
| Component | Measurement to confirm | Typical Birtley specification |
|---|---|---|
| Lift cable diameter | Measure the cable wire diameter with callipers | Typically 3mm for standard canopy doors |
| Cable end fitting | Check whether the cable has a loop end or a swaged stud end at the bottom bracket | Loop end on most Birtley canopy doors. Confirm from existing cable. |
| Cable length | Measure the total length of the existing cable from cone to bottom bracket | Varies by door height. Measure the existing cable before ordering. |
| Cone internal diameter | Measure the bore of the existing cone to confirm shaft fit | Matches the spring shaft diameter. Confirm from existing cone. |
| Cone cable groove | Check the cable groove width matches the cable diameter | 3mm groove for 3mm cable |
Replacing Birtley canopy door cables and cones
- Open the door fully and clamp it securely in the open position on the track. This releases spring tension from the cables.
- Photograph the cable routing and cone positions on both sides before starting.
- At the bottom of the door, the cable end (loop or stud) is secured in a bracket on the bottom rail. Release the cable end from the bracket.
- At the spring shaft, unwind the cable from the cone groove. If also replacing the cone, unscrew or unclip it from the shaft, noting its position and orientation.
- Fit the new cone to the shaft in the same position. Thread the new cable from the top, winding the upper end around the cone groove and routing the cable down to the bottom bracket.
- Secure the cable end in the bottom bracket. Lower the door slowly, checking the cable winds correctly onto the cone and runs without fouling any part of the door frame.
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