Lifeline Measurement Guide

The Yacht Rigger

Accurate lifeline measurements are critical for both safety and proper fit. Small errors can lead to lifelines that are too tight, too loose, or difficult to install. Follow the steps below carefully, and refer to our diagrams throughout the process.

If anything feels unclear, reach out. We’d rather answer a question than have you measure twice.

What You’ll Need

• A steel or fiberglass tape measure (long enough for full runs)

• A fixed reference point (or small screwdriver)

• A printed Lifeline Measurement Worksheet (see below)

• Tape or tags for labeling sections

Important: All measurements must be taken from bearing surface to bearing surface of the fittings.

Step 1: Prepare the Boat

Before removing anything, make sure your system is in its correct working position.

1. Inspect your pulpits and stanchions
   Confirm everything is straight and properly aligned. If anything is bent, repair it before measuring. Measuring against a distorted system will give you incorrect lengths.

2. Tension the lifelines properly
   Bring the system up to normal operating tension.
   A good reference: apply light pressure at the midpoint of the longest span. You should see minimal deflection without pulling stanchions out of alignment or binding gate hardware.

3. Mark your adjusters
   Use tape to mark the position of threaded studs relative to their fittings.
   If possible, measure and note exposed thread length. This allows you to reset your new lifelines to the same baseline tension.

Step 2: Remove and Label Each Section

Remove one section at a time to avoid confusion.

• Disconnect adjusters and carefully pull the wire out of the stanchions

• Immediately tag each section (port forward upper, starboard aft lower, etc.)

• Avoid masking tape. It won’t hold up once the wire is coiled

• Reinstall the adjuster onto its lifeline section after removal

Once removed, coil each section neatly and bring it off the boat for measuring.

Step 3: Measuring Your Lifelines

Use the worksheet and diagrams as your reference.

1. Set adjusters to their marked position
   Lock them in place before measuring

2. Record wire size
   Note upper and lower lifeline diameters separately

3. Measure each section individually
   Measure from bearing surface to bearing surface
   (Refer to diagrams for exact reference points)

4. Identify end fittings
   Use the diagram to indicate which fittings are on each end of every section

Important Measurement Notes

• Measure port and starboard sides separately
  Do not assume symmetry. Differences of several inches are common, even on production boats.

• For boats with gates:
  Lightly push the forward gate stanchion forward and the aft stanchion aft to remove play before measuring.

• Run your tape along the lifeline path
  Keep it parallel to the stanchion holes for accuracy.

• Cross-check totals
  Add up individual sections and confirm they match the full run length.

• Use a proper tape measure
  Steel tapes are preferred for accuracy over long distances.

Material & Configuration Options

We supply lifelines in:

• Uncoated 1x19 Type 316 Stainless Steel (our preferred option)
  Stronger, longer-lasting, and widely accepted for offshore use

• PVC-Coated Wire
  Chosen by some owners for appearance and hand feel

We also offer a full range of hardware options, including:

• Turnbuckles (open or closed body)

• Toggle jaws

• Gate eyes (single or interlocking)

• Pelican hooks - Single handed opening or traditional pull pin style

If you’re unsure what you currently have or what to upgrade to, we can help spec the system.

Final Tips

• Take your time. Accuracy here saves headaches later

• When in doubt, send photos along with your measurements

• If your old lifelines are available, sending them in can help verify your order

Need Help?

This is one of those jobs where details matter. If you have any questions at all, reach out to us directly. We’re happy to walk through it with you.