Swager DIY Tool

[Frank S]

Remember when in doubt grind the dies undersized but don't clamp all the way down in one step clamp down multiple times to achieve the proper finished diameter and do not over swedge as this is just as bad as not swedging far enough. over swedging can deform the wires causing them to break or in the case of using softer sleeves like copper and aluminum they can split open
Back when I was making my elevators I swedged 100's co cables some of the larger 30 to 50 ton freight platforms had as many as 16 cables on them, each needing a threaded thimble on the ends I used a 250 ton hose crimper to do this but randomly sent samples to a 3rd party testing lab in Germany We machined our own studs so this became doubly important to maintain my certification. as my studs were of my own propitiatory design. At the lab we would test the rope and the studs to destruction if possible.
Trust me a machine that is capable of destroying an 80 mm diameter rope had no problem with the largest of my ropes which were only 25 mm

[Sprog]

Trying to build a swaging tool from a Harbor Freight 24" bolt cutter. Need to know the dimensions for the swager opening to crimp 1/8" to 1/4" wire rope cable ferrules. Any information would be appreciated. Larry

Hi Larry,

Some good ideas here, but much as I like making tools, I would be very cautious when dealing with a homemade crimper, particularly if the crimp has to deal with heavy loads (eg porch swing). Professional crimpers are carefully designed and constructed to achieve a guaranteed and repeatable closure pressure for each size of crimp so the crimp does not separate under the specified load. All the best,

Sprog