How to select correct Nicopress sleeves for aircraft cable swaging

When constructing the terminations for aircraft control cables, there are a variety of sleeves that can be used in the swaging process (tin, zinc, copper, etc). The choice is also determined by the cable composition - galvanized or stainless steel. This video explains the proper selection of sleeves for use in aircraft cable swaging.

[@niner_six_echo]

Thanks, Jon. You saved me some cable and fittings (and maybe more). Glad I saw this before I started making cables.

[@jerseyshoredroneservices225]

Thanks for this very informative video. My project is very light duty and non-critical. Just making a safety tether for a GoPro camera on a race car lol. Anyway, I'm still trying to do things properly and this video is helping a lot.

[@ZimmMr]

One video answers all my questions!
Thank you sir!

[@GregsZenithSTOLCH750]

Excellent video, Jon. Thank you!

[@georgewehrung2377]

can you do a video on how to swage? I buggered up the thimble as I had it to close to the sleeve when I used the crimpers. I also have both hand tool with the bolts from ATS to squeeze both sides. Looks like a pair of bars with holes. But, I used the big ‘lock picking’ looking squeezers and just brutalized the sleeve. I also wasnt sure how close to have the thimble to the sleeve.

[@IN_ZANE_]

NICKEL PLATED COPPER?

[@FrancoSailing]

what about of aluminum sleeve in stainless steel cable?

[@flyoran]

thanks for sharing it's very helpful

[@amtpdb1]

Which crimp tool do you suggest and what tool do you suggest for straight shank connectors? Thanks.

[@amtpdb1]

2 years and no reply. Thanks for all your time.

[@tcmixman]

Some
Of the silver ones can also be aluminum. At least in non aviation rigging

[@davetillema8949]

Very informative . Thank you

[@HomebuiltHELP]

Dave: Your email sent to us on May 6 has a bad address - our reply to you was returned to us.

[@OneKoolDude]

Zinc and Tin look very similar, how to tell them apart ??
Is there a P/N stamped on each ??

[@lovetofly32]

That's my question but no part numbers..

[@choppergirl]

This is crazy and the kind of thing that will get you killed (when one fails on your elevator control cable from corrosion on the inside) and you don't know it. The aircraft industry should of picked one or the other.
It's like with crimping RJ-45 connectors with computer networking cable... it was years before I knew there were two different types of RJ-45 connectors for two different kinds of Cat5/6/6e wire... stranded and solid core wire. If you use the wrong connector on the wrong wire, you will forever have your cable ends failing at random and being generally unreliable. The networking industry should of chosen to use one, or the other, but not both.
You can be sure there is no designation on either cable or cable terminators, that one size terminator does not fit all, just like on the nicopress sleeves above, that one size does not fit all, or that even there are two different types of cable requiring different sleeves made out of different material. To make it even worse for inspections, the zinc and the tin look almost identical. The same for the RJ-45 connectors for either stranded or solid cable ... they look the same externally with no indication which is for which.

[@2Phast4Rocket]

This is why aircraft undergoes annual inspection.

[@sridharp9972]

Thanks
நன்றி

[@jerseyshoredroneservices225]

Do aluminum sleeves have a place in this discussion? Aluminum on stainless cable is good or no?

[@ceelo206]

Dissimilar metals cause galvanic corrosion. I wouldn't.

[@jerseyshoredroneservices225]

@@ceelo206
I've read that for stainless cable, tin coated copper is the appropriate material to use for sleeves. That's also dissimilar so I think it's probably more complicated than just dissimilar. I'm not aware that aluminum wire rope even exist so what would the aluminum sleeves be for?