What is Mechanical Swaging

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A coil of 7x7 Stainless Steel Rope
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A coil of 7x7 Stainless Steel Rope

Mechanically Swaged Fittings

This guide will deal with the process of creating a mechanical connection between  G316 Stainless Steel fittings and Stainless Steel Wire Rope.

The process and concepts applies to all diameters and structures of Stainless Steel Wire Rope (albeit, wire rope with a diameter larger than 4.8mm using mechanically swaged fittings - should probably be handled / swaged by a professional as the required tools are quite specialized - and large). And while all structures (7x7, 7x19, 1x19) will (sort of) work - we STRONGLY recommend using 7x7.      For a greater explanation - see our Guide on  "Structures of G316 Stainless Steel Wire Rope"
Mechanical Swager compressing a Ferrule
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Mechanical Swager compressing a Ferrule

How to Swage Fittings


"How do I connect the fittings to the wire?" is actually a good question - and not intuitive if you are not already familiar with the process of swaging (also known as pressing, crimping...)

You actually compress the wire into the ferrule creating a mechanical or interference fit. The connection doesn't have to be as strong as a hydraulic swage as the tension force is held by the thimble and the wire itself.  The crimp merely keeps the wire together and hides the sharp ends (if you do it well...)

The process is that you insert the wire into the ferrule, wrap the wire around a thimble (which is why you need FLEXIBLE wire), re-insert the wire back into the ferrule and then swage/compress the ferrule three times (each end, then the middle) to have the ferrule turn from an Oval into a Tube.  Clearly, you need a tool with some oomph... (we sell such a tool) pictured above.

Our tool has a wide jaw opening which allows very fast application of the tool, it has been factory set with the proper sizing for the ferrules (use the biggest hole for 3.2mm ferrules.   There are other tools out there and tools for various sizes of wire so  please inspect them.  

We strongly recommend that the tool you use is robust and delivers adequate pressure to achieve the swages necessary for proper attachment, that the tool has a a range of 'holes' appropriate for your purpose,  and your vendor has a history of selling and supporting the tools they sell over a course of years.

At Low Cost Wire, we are here to deliver an excellent experience offering advice, service, and excellent prices for both the Professional Tradesperson, the weekend DIY guy/gal, and the inventive individualist / artist / charity.
So grab the fittings, buy/borrow/rent a swager as described, give LCW a call for the more detailed advice - and have a GREAT weekend.  
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