[rebel-builders] flying wires and tools

[Drew Dalgleish]

At 05:51 PM 10/11/2008 -0600, you wrote:

I have to redo some of the structural cables on the 1800 floats for
FOKM. I did not build the floats and have no manual for this. Thus I
need some advice on the tools and materials from someone who knows.

1. I believe the cable is 3/16" diameter, stainless steel. Is that true?

I'm pretty sure that the cable is 5/32" stainless

2. What is the most reasonable tool to buy for crimping the ends? I only
need to do a few.
3. Likewise for checking the quality of the crimp?

The proper tool is really expensive I borrowed one from a local mechanic
that can be bribed with a bottle of rum ;o)It should come with a go-nogo
guage. Check around with other local builders and your RAA, EAA, or COPA
chapter. Even if you had to hire a mechanic to make the cables it would be
way cheaper than buying a tool you'll never use again.

4. Which thimbles would be normal for this purpose?

stainless ?

5. Any special considerations?

Copper nico swages. Having a manual would save you a lot of time and I
believe it's in the CARs that you must have all the appropriate documents
with your plane.

6. What tension and how to measure for these cables?

I just wind them up really tight but I don't know if that's the correct way.
Drew



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[Walter Klatt]

Yes, mine uses 5/32 cables, so the nicos and thimbles must match that size
as well. I have always been able to borrow a nico press tool from someone at
the airport (even one of the shops loaned one to me for a couple of hours),
and their Go-No-Go gauge to check the integrity of the press. I always did

The cables should be aircraft quality, not the galvanized type you find in
hardware stores.

Refer to section 1.35 of MAM's standard practices document for more
information on how to do the swaging.
http://www.murphyair.com/murphyair/Misc ... ctices.pdf

Walter

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com] On Behalf Of Drew
Dalgleish
Sent: October 12, 2008 6:40 AM
To: rebel-builders@dcsol.com
Subject: Re: [rebel-builders] flying wires and tools

At 05:51 PM 10/11/2008 -0600, you wrote:

I have to redo some of the structural cables on the 1800 floats for
FOKM. I did not build the floats and have no manual for this. Thus I
need some advice on the tools and materials from someone who knows.

1. I believe the cable is 3/16" diameter, stainless steel. Is that true?

I'm pretty sure that the cable is 5/32" stainless

2. What is the most reasonable tool to buy for crimping the ends? I only
need to do a few.
3. Likewise for checking the quality of the crimp?

The proper tool is really expensive I borrowed one from a local mechanic
that can be bribed with a bottle of rum ;o)It should come with a go-nogo
guage. Check around with other local builders and your RAA, EAA, or COPA
chapter. Even if you had to hire a mechanic to make the cables it would be
way cheaper than buying a tool you'll never use again.

4. Which thimbles would be normal for this purpose?

stainless ?

5. Any special considerations?

Copper nico swages. Having a manual would save you a lot of time and I
believe it's in the CARs that you must have all the appropriate documents
with your plane.

6. What tension and how to measure for these cables?

I just wind them up really tight but I don't know if that's the correct way.
Drew



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[Garry]

Thanks Walter and Drew. I should be good to go on this now.

Garry

Walter Klatt wrote:

Yes, mine uses 5/32 cables, so the nicos and thimbles must match that size
as well. I have always been able to borrow a nico press tool from someone at
the airport (even one of the shops loaned one to me for a couple of hours),
and their Go-No-Go gauge to check the integrity of the press. I always did

The cables should be aircraft quality, not the galvanized type you find in
hardware stores.

Refer to section 1.35 of MAM's standard practices document for more
information on how to do the swaging.
http://www.murphyair.com/murphyair/Misc ... ctices.pdf

Walter

-----Original Message-----
From: mike.davis@dcsol.com [mailto:mike.davis@dcsol.com] On Behalf Of Drew
Dalgleish
Sent: October 12, 2008 6:40 AM
To: rebel-builders@dcsol.com
Subject: Re: [rebel-builders] flying wires and tools

At 05:51 PM 10/11/2008 -0600, you wrote:

I have to redo some of the structural cables on the 1800 floats for
FOKM. I did not build the floats and have no manual for this. Thus I
need some advice on the tools and materials from someone who knows.

1. I believe the cable is 3/16" diameter, stainless steel. Is that true?

I'm pretty sure that the cable is 5/32" stainless

2. What is the most reasonable tool to buy for crimping the ends? I only
need to do a few.
3. Likewise for checking the quality of the crimp?

The proper tool is really expensive I borrowed one from a local mechanic
that can be bribed with a bottle of rum ;o)It should come with a go-nogo
guage. Check around with other local builders and your RAA, EAA, or COPA
chapter. Even if you had to hire a mechanic to make the cables it would be
way cheaper than buying a tool you'll never use again.

4. Which thimbles would be normal for this purpose?

stainless ?

5. Any special considerations?

Copper nico swages. Having a manual would save you a lot of time and I
believe it's in the CARs that you must have all the appropriate documents
with your plane.

6. What tension and how to measure for these cables?

I just wind them up really tight but I don't know if that's the correct way.

Drew



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