Friday, May 19, 2017
To solve this I decided to Pre-Form the bends on the cable end. They did this on old, WWI, brace wires made from piano wire.
I made a bending jig with some angle iron and dry cell battery terminal nuts. They are just the right radius and they have a groove which perfectly fit the cable. Being made of brass they do not scratch the cable.
There is one nut screwed to the base angle. I drilled out the threads on the one at the pivot for the bender. The pivot bolt is threaded into the base angle. Then there is one nut screwed to the pivot arm. I used nuts with 10-32 threads.
To form the eye we will make 3 bends, one around each nut.
The line scribed on the base is the finished bend line for the first bend.
Then use the block of wood to form the bend around the third nut just like the first bend.
Much better. The 2 cable ends form about a 90 degree angle between each other.
On 1/8" and larger cable always start with the center crimp then crimp the 2 ends.
Crimp the middle then each ends.
Position everything in the cable clamp and mark the cut about 3/16" past the un-crimped sleeve.
Protect the cable with 20 gauge steel and cut off the end of the cable.
The finished terminal leaves just a tiny bit of cable sticking out, as shown on the instructions. Instead of making the cut square, if the cut had been made at about a 15 degree angle, long ends closest to the main cable, there would be even less chance of getting snagged on the free end.
The piece of PVC pipe provides a support for the cable while rotating. Otherwise it just flaps and you can't rotate it while wrapping the end.
You need a cut at about the angle of the twist in the cable so the wrap wire won't slide down the slope while wrapping the end.
This allowed me to heat the cable, with my soldering iron, and sweat them together. You need to let it set for several minutes to cool enough to remove the clamp.
Sweating them together holds them tight for wrapping and make the area stiffer for wrapping.
The wing wires are all double wires. To rotate the cable while wrapping I just used 2 pieces of PVC pipe to hold the cables.
The tube made a nice rest to hold the wound cable while soldering.
I think I'm ready to make the tail surface brace cables for My WACO NINE project.