Wire rope end crimper.

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I posted a few days back looking for a homemade wire rope crimper I had seen on here. (thanks to all that searched for me ) Here is what I came up with. Sorry I didnt get any "in process" pics but Y'all get the the idea.I wanted the tip to be quite hard so it wouldnt mushroom over time. So what I did was endmill a slot 1/8" deep and about 3/8" long in the end of two pieces of 3/4" x 3/8" flat bar. I then welded in a 1/4" x 1/4" chunk of HSS (lathe bit) and welded the two bits of flat bar together. Then ground to a taper.Kinda crappy pic, forgot the macro setting. That gave me a 3/4" x 3/4" "punch" that slides nicely in a bit of 1" 11ga tube. Added a piece of 1" x 1/4" flat bar and machined a slot for a lifting handle (1/4" bolt) Now let me explain why there are 2 grooves in the base.  Because I am an idiot and had set up a 3/8" endmill for another job and forgot to change it out.  This made the groove for the end to sit in too wide and it wanted to move around too much. So a little cussing, a tool change and flipped the part around.Ta-Da, works great. Two stamps on one side and a third in the middle on the other. No need to load check these, but I clamped it in a vice and gave it some good hard yanks and it seems to hold fine.Gratuitous weld pic.  Thanks for looking. LarpIf you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:you can never have too many gratuitous weld pictures. nice job larp.i.u.o.e. # 15queens, ny and sunny fla
Reply:Thanks Doc. If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:Maybe look into nicopress sleeves. That is a very poor way to install those type of terminals.
Reply:Originally Posted by StrangedexMaybe look into nicopress sleeves. That is a very poor way to install those type of terminals.
Reply:Nice welding job Larp, good to see more thinking outside the box. Well done mate.
Reply:If you plan on hanging anything safely use nicopressThere is never enough time to do it right ; But plenty of time to do it over .
Reply:Those eyes are normally roll swaged. Roller swage press is $$. Depending on your application I suspect the crimper will work fine. Proof is on the function. Nicely built for sure. A few years ago I re-swaged an end on a loader control cable using some 3/4" bar with a couple half moons. Lazy manufacturer crimped over the plastic sheathing. Eventually the sheath broken and the cable popped out. Made for a simple fix. Suncor Stainless does have a hand crimp series. I think they are thinner. Uses a crimper similar to the one I built.http://www.suncorstainless.com/hand-swagehttp://www.suncorstainless.com/mini-hand-swager
Reply:I surely envy the craftsmanship you employed in that crimper, but I doubt the crimps will hold if you stress that cable to even 50% it's breaking strength.Consider following up those initial crimps using a hydraulic crimper and crimp the sleeves 100% their length
Reply:While I'm sure you're not stressing these very badly I agree that it's not the best crimp for the job. Here's a selection of home made crimpers that are more suitable for this. The one on the right I made to crimp nicopress wire rope fittings.The hard part is getting ahold of the crimp spec so you can make the hole the right size. Once that's done you can then carefully grind till you get the "dies" made the right size for it to work.I made them out of a cheap import set of bolt cutters for a fraction of what the commercial ones cost.   The two on the left I've made for crimping hose ferrules. However if used in a hydraulic press they would crimp a wire rope end as well.They are easy to make as well. Here's a shot of my building one of them and how I used it in a vice to crimp a ferrule. For full info on these look at this thread. http://weldingweb.com/vbb/showthread.php...ge2&highlight=Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm