After the cable is cut, the next step in making up an
Cutting cables may be accomplished by any
aircraft cable is attachment of the terminals. Most
convenient method except an oxyacetylene cutting
terminal fittings are SWAGED onto the ends of control
torch. The method of cutting usually depends upon the
system cables. Swaging is essentially a squeezing
tools and machines available. If a cable tends to
process in which the cable is inserted into the barrel of
unravel, the ends may be sweat soldered or wrapped
the terminal. Then pressure is applied by dies in a
with a strip of tape prior to cutting.
swaging machine to compress the barrel of the
Small diameter cable may be cut satisfactorily
terminal tightly around the cable. The metal of the
with a pair of heavy-duty diagonal cutters, side cutters,
inside walls of the barrel is molded and cold flowed by
or a pair of wire nippers. Best results are obtained if the
force into the crevices of the cable. Figure 16-29 shows
cutting jaws are held perpendicular to the cable during
two types of hand-swaging tools. The one in the upper
the cutting operation. Cables up to 3/32 of an inch in
part of the illustration is mechanically operated, while
diameter may be cut in one operation by this method.
the lower one is pneumatically operated.
Larger cables may require two or more cuts. When you
When you prepare to swage a terminal, cut the
cut large diameter cables, use the end of the cutting
cable to the required length. Be sure to allow for the
blade, and cut only a few strands at a time.
elongation (increase in length due to stretching) of the
The most satisfactory method of cutting cables is
fitting that will occur during the swaging process. The
with a cable-cutting machine that has special jaws to
amount of elongation will vary with the type and size
accommodate various sizes of cable. See figure 16-28.
of fitting used. Therefore, the elongation must be taken
To use this machine, position the cable in the proper
into account whenever you make up any cable. The
diameter groove and hold the cable firmly within 2
Structural Hardware Manual, NAVAIR 01-1A-8,
inches of the cutting blades. Hold the cable at right
provides elongation data for all types and sizes of
angles to the cutting blades and pull the operating
handle down sharply.
Make sure that the cable end is cut square and clean
A cold chisel and a soft metal block may also be
and that all strands remain in a compact group, as
used for cutting cables. This method should be used
shown in figure 16-30. Place a drop or two of light
only as a last resort because of the way the cable ends
lubricating oil on the cable end. Then, insert the end
into the terminal to a depth of about 1 inch. Bend the
will be frayed.
Figure 16-28.--Cable-cutting machine.