Sender: <marv@lancaironline.net> (Marvin Kaye)
To: lml
Date: Fri, 08 Nov 2002 19:16:42 -0500
Message-ID: <redirect-1856629@logan.com>
From: RWolf99@aol.com
Subject: Swaging Ends on Rudder Cables
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The question on the floor is how to swage ends on a rudder cable segment that 
is threaded thru the S-curve on a set of adjustable rudder pedals.

I took the adjustable pedal assembly out of the airplane and put in on the 
bench.  Then I ran a length of cable through the S-curve, and used my Felco 
cable cutters (like a pair of wire snippers -- these are in the Aircraft 
Spruce catalog) to trim the cable to the proper length.  Then I wrapped a 
small piece of masking tape around the cable end so it wouldn't fray.  Or 
maybe I wrapped the tape first before cutting (this sometimes works better to 
prevent fraying) I just don't remember.

Okay, now I've got two rudder pedal assemblies with wires dangling from all 
four S-curves, and a eight ends that needed to be swaged on.  I carried them 
to the airport and dropped them off with an A&P who DID have the expensive 
swaging tool and picked them up when they were done.  I think I paid $5 per 
swage.

Oh, I must have put the ends on the cables and taped them into place, so the 
swaging guy didn't get them mixed up.  

BTW, this is how I have my firesleeved hard lines done.  This would be for 
firewall-mounted fuel lines (not going between the firewall and the engine -- 
those have to be flex lines).  Brent regan will probably remind us that we 
can also use hard lines if both ends are connected to the engine itself, as 
well.  Anyway, I make the hard line but only flare one end.  Then I slide the 
firesleeve over it and take it to the airport.  The A&P has one of those 
firesleeve clamp pliers and he puts the clamp on.  Then I smoosh the end of 
the sleeve back enough to flare the fitting.

Sure, I'm a tool junkie, but sometimes I just pay the local A&P mechanic who 
has the proper tool to do it for me rather than buy a really expensive tool 
that I'll only use once.  This won't work for Nicopress sleeves, since those 
have to be done on the airplane and you don't have enough money to pay an A&P 
to squish himself back into your tailcone, but your EAA chapter probably has 
a nicopress sleeve squasher that you can borrow.  If not, they should.  And a 
"go-nogo" gauge.

- Rob Wolf