Cable Swaging

[iflywhatevr]

Never swaged anything in my life this was my first attempt with the swaging tool in the builders tool kit. Instruction aren’t very detailed with pics but followed them to the letter and this is what I got. I guess I’m used to seeing the swages with the three much narrower crimps versus one that looks like this. This is for the adjustable rudder cables. How’s it look before I try to do any more.....

https://uploads.tapatalk-cdn.com/20210303/ff404ebabf8a35065c59b86e65581a9c.jpg


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[mattkalin]

27517
This is my example... I used a set of Cable swage pliers as shown in the pic.

[Utah-Jay]

Check this out

https://youtu.be/rmWGR7Qtv0M

[taff]

ifly,

It looks very good, good and tight, professional
Cover only the cable end with shrink tube and it's it.

[jrevens]

Never swaged anything in my life this was my first attempt with the swaging tool in the builders tool kit. Instruction aren’t very detailed with pics but followed them to the letter and this is what I got. I guess I’m used to seeing the swages with the three much narrower crimps versus one that looks like this. This is for the adjustable rudder cables. How’s it look before I try to do any more.....

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I haven't seen "approved" swages done with a single wide crimp like that. I'm curious what "builders tool kit" the tool came from came from... Kitfox? Did it come with a gauge? Generally, a group of 2, 3 or 4 individual crimps are made, depending on cable diameter. I believe this may have to do, at least partially, with allowing the compressed sleeve material to flow properly between swages. That's also the reason the first swage made (in a group of three for instance) is the middle one, and there is definite spacing between crimps . I'm not saying yours is wrong, but just that I don't know. I do know that the Nicopress sleeves used with SS cable must be either tin-plated copper, or SS. Zinc-plated copper or aluminum are not allowed. I'm sure Kitfox knows this and they sell the right ones.

[jrevens]

This is my example... I used a set of Cable swage pliers as shown in the pic.

Matt,

It looks like you may only have 2 crimps on that cable. I know that the size cable used on the newer models requires 3 crimps, FWIW.

[jiott]

I used the swaging tool that came in the kit and it gave me the proper 3 narrow crimps. That single wide crimp does not look right to me.

[iflywhatevr]

I haven't seen "approved" swages done with a single wide crimp like that. I'm curious what "builders tool kit" the tool came from came from... Kitfox? Did it come with a gauge? Generally, a group of 2, 3 or 4 individual crimps are made, depending on cable diameter. I believe this may have to do, at least partially, with allowing the compressed sleeve material to flow properly between swages. That's also the reason the first swage made (in a group of three for instance) is the middle one, and there is definite spacing between crimps . I'm not saying yours is wrong, but just that I don't know. I do know that the Nicopress sleeves used with SS cable must be either tin-plated copper, or SS. Zinc-plated copper or aluminum are not allowed. I'm sure Kitfox knows this and they sell the right ones.

It was in the builders tool kit supplied by Kitfox. The swage tool is similar to this one on Spruce.

https://www.aircraftspruce.com/catalog/topages/swagingtool.php?clickkey=6674


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[Shadowrider]

When you have a question on a critical part, no offense to anyone here, but I would go to the factory.

[taff]

One way out of this,
Post a photo of the tool on this forum.
Is there a brand name on tool that we can google?

Send the same photo to Kitfox and ask the question of, is it an approved tool.
Keeps everyone happy :)

[109JB]

When you have a question on a critical part, no offense to anyone here, but I would go to the factory.

Or an official source like AC 43.13-1B, where it says 3/32 cable gets one press and 1/8" gets 3 presses. I'm not sure what size cable the OP has pictured. On the model 4 I have they used 3/32 cable but I'm thinking the newer models have 1/8" which would mean 3 presses with the proper tool.

edit: BTW the nicopress swaging stuff starts on page 7-32 in AC43.13-1B, available here:
https://www.faa.gov/documentLibrary/media/Advisory_Circular/AC_43.13-1B_w-chg1.pdf

and AC43.13-2B is available here:
https://www.faa.gov/documentLibrary/media/Advisory_Circular/AC%2043.13-2B.pdf

[iflywhatevr]

Or an official source like AC 43.13-1B, where it says 3/32 cable gets one press and 1/8" gets 3 presses. I'm not sure what size cable the OP has pictured. On the model 4 I have they used 3/32 cable but I'm thinking the newer models have 1/8" which would mean 3 presses with the proper tool.

edit: BTW the nicopress swaging stuff starts on page 7-32 in AC43.13-1B, available here:
https://www.faa.gov/documentLibrary/media/Advisory_Circular/AC_43.13-1B_w-chg1.pdf

and AC43.13-2B is available here:
https://www.faa.gov/documentLibrary/media/Advisory_Circular/AC%2043.13-2B.pdf

It’s 3/32 cable that was included with my 7.


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[109JB]

It’s 3/32 cable that was included with my 7.


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Then you are fine. Looks good. Don't forget to put a piece of heat shrink tubing on the cable before swaging the end.

[taff]

It's hard to see in the photo (borrowed from ACS)

ifly, Is this the crimper you have ?

[iflywhatevr]

It's hard to see in the photo (borrowed from ACS)

ifly, Is this the crimper you have ?

No more like this one :

https://www.aircraftspruce.com/catalog/topages/swagingtool.php?clickkey=6674



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[jrevens]

It was in the builders tool kit supplied by Kitfox. The swage tool is similar to this one on Spruce.

https://www.aircraftspruce.com/catalog/topages/swagingtool.php?clickkey=6674


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That's great, David. Those type have been around forever (I have one myself). What you did looks very nice, and the fact that you have 3/32" cable explains everything. I know that the older models used 3/32", but my Series 7SS came with 1/8" (requiring 3 swages), hence the confusion.


https://teamkitfox.com/Forums/images/misc/quote_icon.png Originally Posted by Shadowrider https://teamkitfox.com/Forums/images/buttons/viewpost-right.png (https://teamkitfox.com/Forums/showthread.php?p=98166#post98166)
"When you have a question on a critical part, no offense to anyone here, but I would go to the factory."

No offense to anyone either, but I and others are are, I believe, trying to help others by sharing thoughts and information to keep everyone safe. If I have some doubt about something that may be incorrect or unsafe I'll bring that up on this public forum. If anyone has questions of their own they can certainly contact the factory themselves. Sometimes people make honest mistakes, or changes that may be imprudent or unsafe, and others then follow their example. I think most of us can appreciate that, and the fact that there are those here who may be able to help prevent that.

[taff]

Ifly, your doing good.

If you can hold the tool in the vice. Make sure you real tighten the bolts while you bottom out. don't strip the bolt thread ;)

There is one photo of an 1/8" cable that shows the three compressions. You are using 3/32" cable.

[iflywhatevr]

Thanks everyone for your replies and the good conversation as well. I ended up asking Heather at the factory and sending the picture. She confirmed I should have 1/8 in cable not 3/32. I went off the tag and should have verified in advance as when I measured I confirmed that it was in fact 1/8. She said that although what I did was correct if I had actually had the 3/32 cable it’s incorrect for the 1/8 inch cable and I do need to have the three swages versus the one that is acceptable for the small diameter cable. So off to Aircraft Spruce I go for a replacement nicopress sleeve! At least I figured out my screwup before I got them all done and on the aircraft.

Thanks again for the feedback!

David


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[iflywhatevr]

These look much better. I can tell you that single screw-swage was still pretty strong as it was quite a pain to get it apart so I could save the bushing and make a new one!

https://uploads.tapatalk-cdn.com/20210308/a514fd2cd35a1b7f076e7c21a2f20e5f.jpghttps://uploads.tapatalk-cdn.com/20210308/ed47e2288d53a97d83fafaf089947af9.jpg


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