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Richard Pike
Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee
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 Posted: Sat Jan 21, 2017 5:22 pm Post subject: Trimming raggedy cable ends |
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Spent a few minutes in the garage this afternoon, and this worked so well it needed sharing.
Had a set of used rudder & elevator cables that we are going to be using in the Firefly, they are in good shape except that the ends are pretty ratty. How to trim them off without taking a chance on nicking them?
Use a round x-acto knife blade. Used a screwdriver to spread the blade tang so it would slip over the cable. Work the tapered edge up against the swedge. Clamp the sheet metal vise grips in the vise, used them to hold the cable, and hold the blade tight against the swedge. Used the cut-off wheel on the Dremel and buzzed off the raggedy wires.
Easier to do than tell about. Did all four wires in about ten minutes.
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Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
Forgiving is tough, being forgiven is wonderful, and God's grace really is amazing. |
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mojavjoe
Joined: 23 Dec 2013
Posts: 64
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| Posted: Tue Jan 24, 2017 5:18 am Post subject: Trimming raggedy cable ends |
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Richard;
You wouldn't have had to trim your cable ends if you had used this little trick. It's called spin welding, and it starts by rough cutting the wire cable aprox. 6in. longer than needed, and then clamping vice grips at the point you want the cable to end. Next chuck a drill set to its lowest speed setting to the rigged end of the cable. Since wire cable can be wound clock wise or counter clock wise set the drill to forward or reverse so the drill will tighten the wire. Insure the vice grips will not move (put a brick on them or clamp in a vice). Next heat the wire close to the vice grip jaws to red hot with a torch slowly tighten the wire with the drill while pulling the drill away. The wire will break with the ends fused. Sometimes there might be a wire end or two sticking out of the weld but a file will take care of that.
Joe
From: "Richard Pike" <thegreybaron(at)charter.net>
To: "kolb-list" <kolb-list(at)matronics.com>
Sent: Saturday, January 21, 2017 8:22:28 PM
Subject: Trimming raggedy cable ends
--> Kolb-List message posted by: "Richard Pike" <thegreybaron(at)charter.net>
Spent a few minutes in the garage this afternoon, and this worked so well it needed sharing.
Had a set of used rudder & elevator cables that we are going to be using in the Firefly, they are in good shape except that the ends are pretty ratty. How to trim them off without taking a chance on nicking them?
Use a round x-acto knife blade. Used a screwdriver to spread the blade tang so it would slip over the cable. Work the tapered edge up against the swedge. Clamp the sheet metal vise grips in the vise, used them to hold the cable, and hold the blade tight against the swedge. Used the cut-off wheel on the Dremel and buzzed off the raggedy wires.
Easier to do than tell about. Did all four wires in about ten minutes.
--------
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
There are only two kinds of people in the world. Those who say to God; "Thy will be done."
And those to whom God says ; "OK then; have it your way."
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=465319#465319
Attachments:
http://forums.matronics.com//files/roughjpg_721.jpg
http://forums.matronics.com//files/xactojpg_117.jpg
http://forums.matronics.com//files/bladejpg_106.jpg
http://forums.matronics.com//files/beforejpg_165.jpg
http://forums.matronics.com//files/afte====
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Richard Pike
Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee
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| Posted: Tue Jan 24, 2017 8:03 am Post subject: Re: Trimming raggedy cable ends |
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Joe, I don't think I would do that. Looking up the latest version of Acceptable Methods and Practices:
https://www.faa.gov/regulations_policies/advisory_circulars/index.cfm/go/document.information/documentID/99861
The part about control cables and heat:
https://www.faa.gov/documentLibrary/media/Advisory_Circular/Chapter_07.pdf
7-147.b - it says not to use a torch under any circumstances. I use a well-sharpened chisel, set the cable on a heavy steel dolly, and smack the chisel with a big hammer. Cuts it off clean every time, and then slip a length of heat shrink tubing over the cable before you swedge it. then shrink it to cover
Since this cable came from a different Firestar, it was a case of someone else making it up, and me just trying to make it convenient.
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_________________
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
Forgiving is tough, being forgiven is wonderful, and God's grace really is amazing. |
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wrk2win4u
Joined: 12 Nov 2011
Posts: 30
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| Posted: Tue Jan 24, 2017 11:29 am Post subject: Trimming raggedy cable ends |
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Richard,
Use a Dremel with a mini cutting blade for metal. Use just a little masking tape around the strand before you make the cut.Simply zip through all the strands without disturbing them and unraveling them.
Kurt
Mark III classic
Sent from my iPad
On Jan 24, 2017, at 06:20, "mojavjoe(at)comcast.net (mojavjoe(at)comcast.net)" <mojavjoe(at)comcast.net (mojavjoe(at)comcast.net)> wrote:
| Quote: | Richard;
You wouldn't have had to trim your cable ends if you had used this little trick. It's called spin welding, and it starts by rough cutting the wire cable aprox. 6in. longer than needed, andthen clamping vice grips at the point you want the cable to end. Next chuck a drill set to its lowest speed settingto the rigged end of the cable.Since wire cable can be wound clock wise or counter clock wise set the drill to forward or reverse so the drill will tighten the wire. Insure the vice grips will not move (put a brick on them or clamp in a vice). Next heat the wire close to the vice grip jaws to red hot with a torch slowly tighten the wire with the drill while pulling the drill away. The wire will break with the ends fused. Sometimes there might be a wire end or two sticking out of the weld but a file will take care of that.
Joe
From: "Richard Pike" <thegreybaron(at)charter.net (thegreybaron(at)charter.net)>
To: "kolb-list" <kolb-list(at)matronics.com (kolb-list(at)matronics.com)>
Sent: Saturday, January 21, 2017 8:22:28 PM
Subject: Kolb-List: Trimming raggedy cable ends
--> Kolb-List message posted by: "Richard Pike" <thegreybaron(at)charter.net (thegreybaron(at)charter.net)>
Spent a few minutes in the garage this afternoon, and this worked so well it needed sharing.
Had a set of used rudder & elevator cables that we are going to be using in the Firefly, they are in good shape except that the ends are pretty ratty. How to trim them off without taking a chance on nicking them?
Use a round x-acto knife blade. Used a screwdriver to spread the blade tang so it would slip over the cable. Work the tapered edge up against the swedge. Clamp the sheet metal vise grips in the vise, used them to hold the cable, and hold the blade tight against the swedge. Used the cut-off wheel on the Dremel and buzzed off the raggedy wires.
Easier to do than tell about. Did all four wires in about ten minutes.
--------
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
There are only two kinds of people in the world. Those who say to God; "Thy will be done."
And those to whom God says ; "OK then; have it your way."
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=465319#465319
Attachments:
http://forums.matronics.com//files/roughjpg_721.jpg
http://forums.matronics.com//files/xactojpg_117.jpg
http://forums.matronics.com//files/bladejpg_106.jpg
http://forums.matronics.com//files/beforejpg_165.jpg
http://forums.matronics.com//files/afte====
|
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wrk2win4u
Joined: 12 Nov 2011
Posts: 30
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| Posted: Tue Jan 24, 2017 11:39 am Post subject: Trimming raggedy cable ends |
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Hi Richard,
The easiest way I found to cut strand cables without having them unravel is to use masking tape around the cable before the cut begins. Then use a dermal with a metal cutting disk to sever the cable. That way it does not unravel and remains in the current condition it was in when you put the tape on it.
Kurt,
Mark III Classic
Sent from my iPhone
| Quote: | On Jan 24, 2017, at 09:08, Richard Pike <thegreybaron(at)charter.net> wrote:
Joe, I don't think I would do that. Looking up the latest version of Acceptable Methods and Practices:
https://www.faa.gov/regulations_policies/advisory_circulars/index.cfm/go/document.information/documentID/99861
The part about control cables and heat:
https://www.faa.gov/documentLibrary/media/Advisory_Circular/Chapter_07.pdf
7-147.b - it says not to use a torch under any circumstances. I use a well-sharpened chisel, set the cable on a heavy steel dolly, and smack it with a big hammer. Cuts it off clean every time, and then slip a length of heat shrink tubing over the cable before you swedge it. then shrink it to cover
Since this cable came from a different Firestar, it was a case of someone else making it up, and me just trying to make it convenient.
--------
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
Forgiving is tough. Being forgiven is wonderful.
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=465399#465399
|
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rickofudall
Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA
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| Posted: Tue Jan 24, 2017 7:32 pm Post subject: Trimming raggedy cable ends |
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Or, you could get one of these:
https://smile.amazon.com/Felco-C7-wire-cutter-ea/dp/B0006229UQ/ref=sr_1_1?ie=UTF8&qid=1485314793&sr=8-1&keywords=felco+cable+cutters
I don't remember what I paid for mine 45 years ago, but back then I was making about $2.50 an hour so I'm sure it wasn't $60. Still they cut like they did when they were new so I guess a quality tool does last a lifetime.
Rick Girard
On Tue, Jan 24, 2017 at 1:29 PM, K I <wrk2win4u(at)msn.com (wrk2win4u(at)msn.com)> wrote:
| Quote: | Richard,
Use a Dremel with a mini cutting blade for metal. Use just a little masking tape around the strand before you make the cut. Simply zip through all the strands without disturbing them and unraveling them.
Kurt
Mark III classic
Sent from my iPad
On Jan 24, 2017, at 06:20, "mojavjoe(at)comcast.net (mojavjoe(at)comcast.net)" <mojavjoe(at)comcast.net (mojavjoe(at)comcast.net)> wrote:
| Quote: | Richard;
You wouldn't have had to trim your cable ends if you had used this little trick. It's called spin welding, and it starts by rough cutting the wire cable aprox. 6in. longer than needed, and then clamping vice grips at the point you want the cable to end. Next chuck a drill set to its lowest speed setting to the rigged end of the cable. Since wire cable can be wound clock wise or counter clock wise set the drill to forward or reverse so the drill will tighten the wire. Insure the vice grips will not move (put a brick on them or clamp in a vice). Next heat the wire close to the vice grip jaws to red hot with a torch slowly tighten the wire with the drill while pulling the drill away. The wire will break with the ends fused. Sometimes there might be a wire end or two sticking out of the weld but a file will take care of that.
Joe
From: "Richard Pike" <thegreybaron(at)charter.net (thegreybaron(at)charter.net)>
To: "kolb-list" <kolb-list(at)matronics.com (kolb-list(at)matronics.com)>
Sent: Saturday, January 21, 2017 8:22:28 PM
Subject: Trimming raggedy cable ends
--> Kolb-List message posted by: "Richard Pike" <thegreybaron(at)charter.net (thegreybaron(at)charter.net)>
Spent a few minutes in the garage this afternoon, and this worked so well it needed sharing.
Had a set of used rudder & elevator cables that we are going to be using in the Firefly, they are in good shape except that the ends are pretty ratty. How to trim them off without taking a chance on nicking them?
Use a round x-acto knife blade. Used a screwdriver to spread the blade tang so it would slip over the cable. Work the tapered edge up against the swedge. Clamp the sheet metal vise grips in the vise, used them to hold the cable, and hold the blade tight against the swedge. Used the cut-off wheel on the Dremel and buzzed off the raggedy wires.
Easier to do than tell about. Did all four wires in about ten minutes.
--------
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
There are only two kinds of people in the world. Those who say to God; "Thy will be done."
And those to whom God says ; "OK then; have it your way."
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=465319#465319
Attachments:
http://forums.matronics.com//files/roughjpg_721.jpg
http://forums.matronics.com//files/xactojpg_117.jpg
http://forums.matronics.com//files/bladejpg_106.jpg
http://forums.matronics.com//files/beforejpg_165.jpg
http://forums.matronics.com//files/afte====
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--
“Blessed are the cracked, for they shall let in the light.” Groucho Marx
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The smallest miracle right in front of you is enough to make you happy.... |
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Richard Pike
Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee
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| Posted: Tue Jan 24, 2017 8:32 pm Post subject: Re: Trimming raggedy cable ends |
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Kurt - Rick - Joe - Thank you for your ideas. But the original control cables from the original Firestar we got were destroyed, so we trashed them and kept the cables from the FSII basket case / kit that we sold, these are the cables pictured. These cables are what we are going to use in our do-it-yourself Firefly. These cables are all fuzzed, and the point of this post was to help someone whose cables are also fuzzed.
Your ideas are great for someone making up cables from scratch. Great ideas. (Except for the torch. Not so sure about the torch)
Thanks
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_________________
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
Forgiving is tough, being forgiven is wonderful, and God's grace really is amazing. |
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adcon4(at)gmail.com
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| Posted: Wed Jan 25, 2017 6:47 am Post subject: Trimming raggedy cable ends |
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On Tue, Jan 24, 2017 at 11:35 AM, K I <wrk2win4u(at)msn.com (wrk2win4u(at)msn.com)> wrote:
| Quote: | --> Kolb-List message posted by: K I <wrk2win4u(at)msn.com (wrk2win4u(at)msn.com)>
Hi Richard,
The easiest way I found to cut strand cables without having them unravel is to use masking tape around the cable before the cut begins. Then use a dermal with a metal cutting disk to sever the cable. That way it does not unravel and remains in the current condition it was in when you put the tape on it.
Kurt,
Mark III Classic
Sent from my iPhone
> On Jan 24, 2017, at 09:08, Richard Pike <thegreybaron(at)charter.net (thegreybaron(at)charter.net)> wrote:
>
> --> Kolb-List message posted by: "Richard Pike" <thegreybaron(at)charter.net (thegreybaron(at)charter.net)>
>
> Joe, I don't think I would do that. Looking up the latest version of Acceptable Methods and Practices:
>
> https://www.faa.gov/regulations_policies/advisory_circulars/index.cfm/go/document.information/documentID/99861
>
> The part about control cables and heat:
>
> https://www.faa.gov/documentLibrary/media/Advisory_Circular/Chapter_07.pdf
>
> 7-147.b - it says not to use a torch under any circumstances. I use a well-sharpened chisel, set the cable on a heavy steel dolly, and smack it with a big hammer. Cuts it off clean every time, and then slip a length of heat shrink tubing over the cable before you swedge it. then shrink it to cover
>
> Since this cable came from a different Firestar, it was a case of someone else making it up, and me just trying to make it convenient.
>
> --------
> Richard Pike
> Kolb MKIII N420P (420ldPoops)
> Kingsport, TN 3TN0
>
> Forgiving is tough. Being forgiven is wonderful.
>
>
>
>
> Read this topic online here:
>
> http://forums.matronics.com/viewtopic.php?p=465399#465399
>
>
>
>
>
>
>
>
>
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Richard Pike
Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee
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| Posted: Mon Jan 30, 2017 7:43 pm Post subject: Re: Trimming raggedy cable ends |
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| mojavjoe wrote: | Richard;
You wouldn't have had to trim your cable ends if you had used this little trick. It's called spin welding, and it starts by rough cutting the wire cable aprox. 6in. longer than needed, and then clamping vice grips at the point you want the cable to end. Next chuck a drill set to its lowest speed setting to the rigged end of the cable. Since wire cable can be wound clock wise or counter clock wise set the drill to forward or reverse so the drill will tighten the wire. Insure the vice grips will not move (put a brick on them or clamp in a vice). Next heat the wire close to the vice grip jaws to red hot with a torch slowly tighten the wire with the drill while pulling the drill away. The wire will break with the ends fused. Sometimes there might be a wire end or two sticking out of the weld but a file will take care of that.
|
Joe - You da Man! Spent today redoing the elevator and rudder control cables, and despite my best efforts, could not get some of those old wires to go through the nico sleeves. Remembered this post, and had my brother in law clamp one side of the extra length of wire in one clamp, I held the other wire in a clamp and used the torch to get the intervening piece of wire red hot. He twirled it off, and it slipped through that nico slicker than whiz! Since it was a couple inches from where we heated it to where we ended up cutting it off, the heat was not an issue, so my previous misgivings were a non issue. Thank you! 
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_________________
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
Forgiving is tough, being forgiven is wonderful, and God's grace really is amazing. |
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adcon4(at)gmail.com
Guest
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| Posted: Tue Jan 31, 2017 1:12 pm Post subject: Trimming raggedy cable ends |
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canceld
On Mon, Jan 30, 2017 at 7:43 PM, Richard Pike <thegreybaron(at)charter.net (thegreybaron(at)charter.net)> wrote:
| Quote: | --> Kolb-List message posted by: "Richard Pike" <thegreybaron(at)charter.net (thegreybaron(at)charter.net)>
mojavjoe wrote:
> Richard;
>
> You wouldn't have had to trim your cable ends if you had used this little trick. It's called spin welding, and it starts by rough cutting the wire cable aprox. 6in. longer than needed, and then clamping vice grips at the point you want the cable to end. Next chuck a drill set to its lowest speed setting to the rigged end of the cable. Since wire cable can be wound clock wise or counter clock wise set the drill to forward or reverse so the drill will tighten the wire. Insure the vice grips will not move (put a brick on them or clamp in a vice). Next heat the wire close to the vice grip jaws to red hot with a torch slowly tighten the wire with the drill while pulling the drill away. The wire will break with the ends fused. Sometimes there might be a wire end or two sticking out of the weld but a file will take care of that.
>
>
Joe - You da Man! Spent today redoing the elevator and rudder control cables, and despite my best efforts, could not get some of those old wires to go through the nico sleeves. Remembered this post, and had my brother in law clamp one side of the extra length of wire in one clamp, I held the other wire in a clamp and used the torch to get the intervening piece of wire red hot. He twirled it off, and it slipped through that nico slicker than whiz! Since it was a couple inches from where we heated it to where we ended up cutting it off, the heat was not an issue, so my previous misgivings were a non issue. Thank you!
--------
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
Forgiving is tough. Being forgiven is wonderful.
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=465592#465592
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eferrer" target="_blank">http://forums.matronics.com
====================================
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errer" target="_blank">http://wiki.matronics.com
====================================
b Site -
-Matt Dralle, List Admin.
rel="noreferrer" target="_blank">http://www.matronics.com/contribution
====================================
|
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