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Jorge&Cindy
12-03-2008, 03:24 PM
Spent some time learning a new skill. Twenty minutes and one messed up Nicopress sleeve, I think I got it. I just need verification from the gallery that I did it right. Not too tight or too loose on the loop? Anything else I missed? Thanks.

One side.http://img258.imageshack.us/img258/3385/dsc01619xs8.jpg (http://imageshack.us) Other side.http://img530.imageshack.us/img530/6494/dsc01622dl1.jpg (http://imageshack.us)

DanB
12-03-2008, 03:53 PM
Jorge,

To the eye your work looks fine, however, I learned about a go-no go card and how they take the guesswork out of doing it right. see part way down this web page: www.azshowersolutions.com/Fuselage11.html (http://www.azshowersolutions.com/Fuselage11.html)

Jorge&Cindy
12-03-2008, 05:26 PM
It's actually not right. I guess I pulled the cable too tightly thru the sleeve and the squeezing action of the tool, stretches the sleeve out slightly. I tried to line up the washer that will eventually be used in installing the cable, and it butts up against the sleeve not allowing the holes to line up. One more try. I'll be ordering one of those gauges. Thanks

airlina
12-04-2008, 05:41 AM
Also Jorge to keep the cut end from turning into a frazzled mess that will sting you every time you get near it, I first tape the area that I will cut with electrical tape then cut thru the taped area. Then I slip a piece of shrink fit tube over the cable before swaging and once the swage is complete, slide the tube over the swage and cable and heat shrink in place for a nice finished look. Bruce Lina N199CL

Jorge&Cindy
12-04-2008, 07:36 AM
Hey Bruce,
Did all that , came out pretty, but too tight. Thanks for the help. By the way, how did you cut the cable? I used my Dremel, but that gets the cable real hot.

http://img393.imageshack.us/img393/4191/dsc01624fp8.jpg (http://imageshack.us)

mcguif0a
12-04-2008, 11:02 AM
To cut the cable I just used normal plyers but it was tough.

DanB
12-04-2008, 01:20 PM
The best way I found to cut the cable was to use a sharp cold chisel and a scrap piece of aluminium for the backer. Do it on the concrete floor and it works great. One whack w/ a hammer usually does it. Don't forget the safety glasses (Sorry, it's the shop teacher comming out)

kmul
12-04-2008, 04:13 PM
jorge, the washer on mine also butted against the swaged nicopress. i just filed a relief in the washer and installed it that way. alot less work than doing it over. good that you are getting the guage.

airlina
12-05-2008, 06:40 AM
Looks good Jorge-I cut the cable one of two ways, If I am simply cutting a piece to length I use a big bolt cutter that I got at harbor freight.However there are times like you are finding out that you must be a bit more surgical about the process, such as cutting the tail of the cable after it wraps around a thimble or eye. In this case, I use a dremel tool . I first put a piece of scrap aluminum or thin steel in between the "good" cable and the one I will cut off to be absolutely sure that I do not nick the good cable with the dremel bit. Good luck Bruce N199CL

RandyL
12-06-2008, 01:53 PM
Double-swaging, interesting idea, and certainly an easy thing to do. Anyone else done this or think it's a good idea? Have there really been failures? I'll be doing my cables shortly and now would be the time for me to make a decision on this.

vetdrem
12-06-2008, 02:22 PM
It is my understanding that a properly installed swage is stronger than the cable itself. It is a good idea to check the installation using a "go-no go" gauge, or measuring it with a mic to make sure. If it's correct, the second swage shouldn't be needed.

Louie

vetdrem
12-06-2008, 05:36 PM
I can think of many, many tasks associated with building an aircraft that are more difficult to do correctly than swaging a cable. Thousands of amature builders have accomplished hundreds of thousands of these tasks with great success. I am sure that there have been failures, as with anything, but given due diligence, this is NOT a task that is beyond amature builders.

Louie

RandyL
12-07-2008, 10:01 AM
Good topic and a timely one for me. Does the expensive ($234) Nicropress tool yield better results than the "economy tool", or is it just a matter of convenience & speed?

Nicropress expensive swager...
http://www.aircraftspruce.com/catalog/topages/swagingtool.php

kmul
12-07-2008, 11:23 AM
i cant tell you which is better but i have the expensive one. it can feel awkward until you have used it a couple times. mine came set too tight so suggest a test swage first. integral cable cutter cuts cleanly. found that somtimes the initial and middle swage would guage ok but not always after the swage next to it done. just a matter of another squeeze and reguage it. i guess this would happen with the cheapo one too. i like it. maybe is not worth the extra $ for occasional use but if you like good tools its nice.

Mark
12-08-2008, 03:40 AM
I have had to remove cables before by removing the swaged sleeve. The first time I cut into one, I thought I could cut one side of the sleeve between the cables and it would pop right off. When I cut it open, I could not budge the cable from the sleeve. Then I cut the other side of the sleeve. Neither half would move on the cable. It took two pairs of vice grips to pry each sleeve half from the cable. What happens in a proper swage is that the sleeve actually blends and forms itself into the cable. (By the way, the swage was made using the No. 1 Hand Swager (expensive one). The cable cutter on that thing is incredible. I also use it for swaging the electrical terminals on the #6 wire used for the battery and starter wiring.) Maybe your local EAA has one you can borrow.

I believe that most builders can produce better quality than a factory. By taking the time to make a proper swage, the rudder cables are the last thing you're going to worry about. As for double swaging, if it makes you feel good, go for it. An ounce (or six ounces) of prevention is worth a pound of peace of mind...

Bryan
12-08-2008, 10:49 AM
For what it is worth, I was informed several years ago NOT to double swage cables. The reasoning behind this was that unless done perfect there would be more slack in one piece of cable between the two swages. This would allow the two pieces of cable two work against each other and cause them to loosen. Example: between your hands hold two pieces of rope and leave one looser than the other and then try pulling on the two and after a while they would both be the same. The question then would be did only one let the rope slide or did both allow movement? I was told to take the time to do the one properly and you will never have a problem. I have a friend that helped me and we actally tested a swaged cable to failure. The cable failed before the swage. This was with the single swage. I hope this all made sense to everyone. We were using the high dollar swaging tool.

Jorge&Cindy
12-08-2008, 02:17 PM
Only time I can find where double swaging is acceptable is when doing a repair or splice to a cable:

Double swage
http://img100.imageshack.us/img100/4372/doubleswagxq8.png (http://imageshack.us)
Single swage
http://img122.imageshack.us/img122/1572/thimbleaa8.png (http://imageshack.us)

Agfoxflyer
12-08-2008, 04:06 PM
I have had plenty of practice swaging cables on my Series 5. I had three sets of cables on my plane before it ever flew. Let me explain. When the kit was delivered in 1998 the nicopress sleeves were copper. A few months after I installed the cables, Skystar issued a service bulletin. Stainless steel cables and copper sleeves do not get along. SB said to replace. So I did. Being the first time I had ever done swaging, I thought mine looked good. However after looking at pictures I decided to redo the whole process again for the third time. Fortunately only about $20 worth of cable each time. I have both the cheap swager and the "glorified bolt" cutter with swaging jaws. I found the cheap one akward. The more expensive one (not the most expensive one) was about $140.

Skybolt
12-17-2008, 03:52 AM
I know... a little late, I was looking at the earlier questions about how to cut cables.

http://www.aircraftspruce.com/catalog/topages/felcocutters.php

I have the model # C-7F.
Well worth the investment, easy cutting, clean edges and easy to thread.

Cheers. Eric

FoxBob
01-10-2010, 08:07 PM
So, it would appear that the swage should be about as close to the bushing as you can manage, but perhaps just far enough away so that the washer doesn't overlap the swage.

TGio
01-12-2010, 08:44 AM
Check out the Loos and Co web site for demos and information on swaged cable. I prefer to cut cable with the hand operated cable cutters, makes for a clean edge. I use torque seal for cable slippage inspection, after proof testing the assembly. Safety...
http://www.loosnaples.com/home.php

DanB
01-12-2010, 03:50 PM
I have found a very good way to cut the cable is to wrap it with tape and use a diamond cut-off wheel on the dremel. Comes out nice every time.

Lion8
01-12-2010, 07:00 PM
Some of the Aviation supply company's we all deal with, sell a very nice cable cutter. Does a great job. Cuts cable up to 3/16". Only 25 bucks. ope this helps.-Lion8