Swaging is a method for metal forming that requires specific machinery for application. Swaging is the process of shaping or forging metal through a series of very fast blots delivered by hammers or other tools.
They are used for large and small-scale assembly applications. When swaging is used during assembly application, there are two metal pieces that are forcefully compressed, and they are bonded and conjoined together.
Around the cable, there is a circular shape that is kept when swaging is done for the purpose of an assembly application.
To prevent movement of the cord, a wire rope is swaged by using a crimping tool. However, crimping tools can be quite expensive, and it might not be a worthwhile investment if you only plan to use them once. However, you’re in luck because today, we will look at how to stage wire rope without using any particular tools.
In order to swage able, there are several tools you probably have at home that you can use. Some of the most common tools that are used as swaging tools are pliers, chisel, hammer, a vise grip, aluminum ferrule/sleeve, or cable. Below, we will go more in-depth about how to swage wire rope without a tool.
Different Methods to Swage Your Wire
How To Swage with A Plier
- Step 1 – Ferrules will have one wire go through one end of them. You need to feed them into the other end of your ferrule by forming your wire into a small loop. Make sure that section of wire matches on both ends by measuring it.
- Step 2 – Then, use a hammer or a set of pliers to press down the sleeves. You can press down the ferrules or smaller wire gauged by using a set of pliers or a hammer. Use a surface that is metallic and that you don’t mind damaging to hammer the ferrules down if you’re using a plier. In order for the ferrules to grip the wire, you need to use as much pressure as you can.
- Step 3 – Lastly, you need to test the wires by using your body weight to pull them. You will have swaged wire without any particular tools if your wire ropes do not budge and feel snug.
Swaging Cable with Vice Grip
A swage a cable with a vice grip, you will need a big vice grip, an aluminum or ferrule sleeve, and a cable which you want to swage.
All you need to do is take an aluminum sleeve or ferrule in accordance with the diameter of the cable you want to swage. Then, you need to pass the cable throughout the aluminum sleeve or ferrule. At one end of the cable, make a loop and pass it into the ferrule or aluminum cable back. Depending on the size you want it to be, adjust the loop of the cable.
After you’ve done this, you need to place the sleeve vertically inside the jaw of the vise grip. Hold it by pressing lightly and then tighten the setting of the vise grip. Lastly, make more than one swage side by side by repeating this.
Some tips are to keep a minimal space between the swages while you make them and always place the sleeve inside vertically instead of horizontally.
How to Swage Cable Using Chisel and Hammer
One very effective method to swage a cable is with a hammer. However, you will need to put in a bit more effort. You will need a hammer, ferrule, and a cable.
You need to get an aluminum swage sleeve according to the cable size you have and make a loop by entering the cable through the ferrule and passing it back. You can adjust the size of the loop according to your needs. Once the chisel is in the sleeve, you can whack it with a hammer. Lastly, make two or three dents on the sleeve.
Keep in mind that you can use safety gloves in order to avoid any missed hits, and be extra careful when you’re striking the hammer.
General Tips
Remember the following tips when swaging cable without any swage tool.
If you’re swaging a cable with a hammer, make sure you don’t break it by bashing it too hard. If you’re swaging an electric cable or wire with a hammer, keep in mind that it can be really dangerous. While you’re doing this, make sure you carefully use the tool.
You need high pressure to create a secure and proper swage. In case you have a low-diameter cable, you can only use pliers. If you’ve never used these types of tools before, it might happen that you break one or two sleeves on your first try. However, after you’ve gone through the process once or twice, you will easily get the hang of it, so don’t get discouraged after the first time.
It is good to use aluminum crimps for monofilament and copper ferrule or crimps for cable swage. Both of these cause no issue and are usable.
Final Thoughts
Even though using a proper tool to swage is the best choice, that isn’t always an option for people. Sometimes, you’re missing the proper tool to swage.
However, if you know how to handle a swaged cable without a tool, you can save some money and a trip to the store. You can use many different items instead of the proper swage tool, like the ones we mentioned above.
As other skills take time to be learned, wire rope swaging also can be a bit complicated in the beginning. However, the process is simple, and you will quickly get the hang of it.
