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Old 03-02-2014, 01:47 PM   #1
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Miami , Florida
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Swaging 1/4 aviation wire

Hi all. This is my first post here. I need to be pointed in the right the direction. I would like to swage(?) and 1/4" nylon coated aviation wire with a single shank ball but, I have no idea how to do it or what tool I should use. Thanks in advance.

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Old 03-02-2014, 02:32 PM   #2
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I am familiar with swaging copper tubbing but never heard of it for wire. So I just had to look it up. Not the same process at all. Here's a site I found. Doesn't look like a job for someone wanting to only do it once. The tools look expensive.

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Old 03-02-2014, 02:54 PM   #3
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I'd see what is available from nicopress.

If you're working on planes, see

However, 1/4" is big for planes.

Single Shank Ball MS20664

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Old 03-02-2014, 03:46 PM   #4
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Check with a local aviation maintenance organization. they make the swage fitting MS20664C8, the tool to do it is pretty expensive so the mtc. outfit can tell you if they can do it or point you in the right direction.The coating will have to be removed for the swage though.....Phil.
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Old 03-02-2014, 04:06 PM   #5
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find a yacht rigger near you. they can do it.
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Old 03-07-2014, 09:02 PM   #6
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I love to swage. I bought my first swaging tool a few years ago, and I'm amazed at all the uses I keep finding for doing things with stranded cable instead of rope or whatever. For example, my backyard hammocks hang from cable. They stay put with no stretching. That said, the upfront investment is pricey. Especially when you get into larger cables, like 1/4". I only go up to 5/32", which has something like 2000lb break strength.

You also need a good way to cut the cable. Regular wire cutters are no good, nor are bolt cutters. I bought a Felco C7 which is amazing, but also $65 for a little hand tool. Then I trolled eBay for awhile to find a used pair of the ferrule crimpers to do the 5/32 cable, and the Nicopress swaging crimper was around $70. Very happy with the results though.

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