Unfortunately, when most manufacturers use aluminum, they continued the same production methods they used to build steel lifts. Aluminum is very easy to weld, and with proper methods on proper alloy, it works great; but if the proper conditions are not met, it can be disastrous. Welded heat-treated aluminum is much weaker than bolted. Most manufacturers have adjusted their projection to cut out welding altogether and use only mechanical fasteners, we try to follow the same ideals.

All aluminum boat lifts are made of 6061-T6 aluminum, which is usually all that is available in the large structural shapes we use. Any aluminum alloy with a T in its description means it is heat-treated. The heat treatment gives it the tremendous rigidity necessary to carry heavy loads. Unfortunately, reheating the material (welding it) will reverse the process, and a huge percentage of the strength is gone.

There are no load-bearing welds on a Synergy Boat Lift. Welding is much faster and less ratio of a chain drive will be comparable, it is very unlikely the industrial-grade gearboxes on the Synergy Boat Lift will fail.

Gear driven boat lifts typically use a “double reduction” gearbox. This is a small gearbox couple to a much larger gearbox. The combination creates a mechanical advantage of the ratio of the small box times the ratio of the large box. This means that for every 450 revolutions the motor turns, the lift will turn 1.

A typical Synergy Direct Drive gearbox is part of our “Intelligent Design” concept. This means the internal shaft position is at the bottom, the gear contact surfaces are always immersed in lubricant. These gearboxes are rated for 24-7 duty, so the infrequent usage of a boat lift is a very safe application.

Some may think a stainless steel shaft would be better. However, the stainless steel shaft does not have the torsion strength necessary for a boat lift. Our structural engineer will not certify a lift with a stainless steel shaft. At Synergy, we wrap our cables on a grooved aluminum winder. This protects the shaft from wear from cable chafing. We also run our shafts through an extruded polymer bushing. They are 100% maintenance-free, and our driveshafts are guaranteed parts and labor for as long as you own the lift.

Synergy uses industrial grade, high-duty cycle motors. These are designed to be used for constant duty in an industrial application. At Synergy, our motors and gear drives are totally enclosed by a weather resistant cover. We do not use a stainless steel motor, but a painted motor. Unfortunately, the longevity of a stainless steel motor is limited, with our painted motor, the money goes into the machine.

Before shipping, we install the gearboxes, motors and covers. The motor wiring is routed into an outdoor rated electrical box. The electrician does not need to remove the drive cover to wire the lift. This is a big money saver. Synergy warranties its motors and gear drives for 5 years.

The lift cradle is made up of two or more aluminum “I” beams, which are suspended by cables from the top beams. In most applications, there is a sheave (pulley) attached to the end of the beam. The cable attaches to the top lift, the cable length can be adjusted at the deadman. Most of the lifts now have this, but not all. If the cable is not externally adjustable, the cost of installation, and future cable replacement will be much higher.

Synergy cradle ends bolt through the vertical web of the beam which is the load bearing member. The lower edge of the bracket presses against the bottom flange of the beam, and the upper part of the bracket presses into the upper flange. This distributes the load over the entire end of the beam. This creates the strongest cradle end in the industry.

Attached to the upper part of the brackets is the pulley mount. This part positions the pulley aligned with the cable winder. Note how the cable enters and exists the pulley tangent to the circumference, not parallel as in Figure 3 (see next page). This is a benefit since it nearly eliminates pulley and cable chafing and wear. There is also a grease fitting on the axle. Grease once or twice a year can save you a lot of money.

See Photos below for comparison of some significant design flaws.

1. The bracket slides onto the top flange of the cradle beam. This horizontal flange was never designed to carry a load.
2. The sheave (cable pulley) is facing the wrong direction. As the cables wind along the grooved winder in the top beam, they move horizontally. This creates what is fleet angle. If you look at the image, you will see how the cables enter and exit the pulley at angles (fleet angle). This causes tremendous cable and pulley wear.
3. The same image does not have a grease fitting in the axle bolt. There are “self-lubricating” bushings available, and in certain applications, they work. The problem is: the grease is not on there only to lube the axle, but also to create a barrier between the pulley and the mount structure. If there is nothing in between, over time there will be a salt buildup, which will cause the pulley to seize. This can be a very expensive repair.

Where we lead in the industry with the strongest and most reliable boat lifts:

• Welding vs. mechanical fastening. Welding is quick and inexpensive. Mechanical fastening is not cheap, not quick, more expensive, but MUCH STRONGER.
• Driveshaft bushings vs metal-to-metal. Our bushings and shafts are guaranteed parts and labor as long as you own the lift.
• Hull guides are “tabbed” on or positively fastened.
• Motors and gearboxes are totally enclosed.
• Cradle sheave mounts toggle to eliminate excessive wear.