Golden Gate Bridge Cable Saddle

This is a 1/100 scale reproduction of a cable saddle of the Golden Gate bridge in San Francisco, California. The cable saddle supports the main cable of the suspension bridge over the top of the bridge tower, transferring the enormous weight of the cable, suspender ropes and bridge deck onto the tower and its massive foundation below. The Golden Gate Bridge is a beautiful example of the balance between form and function, being endowed with a great measure of both; its elegant form is made possible by the structural function of this cable saddle.

The model was designed from dimensioned drawings and photographs published in the 1937 report of the chief engineer to the Board of Directors of the Golden Gate Bridge and Highway District, by chief engineer Joseph B. Strauss. Each of the four saddles on the Golden Gate Bridge consists of three massive steel castings bolted together and hoisted atop a cap plate at the top of the bridge's main towers, located at an elevation of 734 feet (224 meters) above the water. The saddle castings were hoisted into place in November of 1934 for the north tower, and June 1935 for the south tower. Each cable saddle rests on a set of roller bearings (not visible) that allowed it to shift longitudinally as the suspended structures were gradually built up, and the towers and cable flexed to their final alignment. The model reflects the modern condition of the bridge, with the original rotary light beacon removed and perimeter handrails added.

The model of the cable saddle was developed for a 1/100 scale replica of an entire tower of the Golden Gate Bridge, standing 7 feet 6 inches (2.3 meters) tall. At this scale, the entire bridge would stretch 90 feet (27 meters) long, much too big to fit in a living room! While the cable saddle looks best as part of a larger model (not included), it also makes a great conversation piece by itself when mounted on a display base.

The cable saddle a complicated shape uniquely suited for 3D printing. It comes protected by a shipping and handling sprue, to prevent damage to handrails and other small details. Only a few liberties were taken with the dimensions; the handrails and ladder are slightly oversized for mechanical integrity, and the entire piece is longitudinally symmetrical while the prototype's main cable arrives at a slightly different angles from the main span and side span to either end. Note this model has delicate and fragile details and is intended for display only.

The model is shipped unpainted directly from Shapeways and will require some finishing steps before it is ready for display:

1. Don't remove the shipping and handling sprue just yet!
2. Set in direct sunlight for about an hour to complete ultraviolet curing of the material.
3. Submerge gently in warm (not hot) water mixed with dish detergent to remove any waxy residue left from the printing process.
4. Rinse gently using cold water.
5. Air dry thoroughly.
6. Remember, the key to a good paint job is prep work. Don't skip or rush any of the above steps.
7. Finish using acrylic paint, preferably by spray application, or (very patiently and carefully) with a brush. Start with recessed areas and watch out for those fragile details. While some paints are sold as "International Orange," the same name given to the color of the bridge, they will turn out too bright. For an authentic look, mix up a dark reddish orange similar to the color Pantone 174, or a bit lighter to compensate for the color scale effect.
8. As late as possible to prevent handling damage, remove shipping and handling sprue by cutting at the four corners of the perimeter catwalk. Use a sharp pair of flush cutting pliers and watch out for the fragile handrails nearby.
9. Secure to display base of your choice (for example wooden 4 x 6", not included) using double-sided tape. If you wish to perch the saddle on a short section of tower (not included), the scale size of your tower section will need to be 75 x 32 mm.