How to install a wire rope ferrule and end stop?

Step-by-Step Guide: Installing a Wire Rope Ferrule and End Stop

Tools and Materials Needed

Before you start, gather the necessary tools and materials:

Materials

• Wire rope – Ensure you have the correct diameter and type for your application.
• Ferrule (Sleeve) – Choose the right material (aluminum, copper, or stainless steel) and size based on the wire rope’s diameter.
• End stop – A small cylindrical fitting used to prevent the wire rope from slipping out of a fixture.
• Thimble (Optional) – Used when making a loop to protect the wire rope from wear.

Tools

• Wire rope cutters – For a clean cut without fraying.
• Crimping tool or swaging tool – A hand swager, hydraulic crimper, or bench-mounted press.
• Measuring tape – To ensure proper loop size.
• Marker or chalk – For alignment.
• Gloves and safety glasses – For protection.

Step 1: Select the Correct Ferrule and End Stop

• The ferrule size should match the wire rope diameter.
• Ferrule material selection:
  • Aluminum ferrules – Common for general applications.
  • Copper ferrules – Used for stainless steel wire rope to prevent corrosion.
  • Stainless steel ferrules – Used for marine or high-corrosion environments.
• End stops are typically cylindrical crimps used to cap the end of the wire rope.

Step 2: Cut the Wire Rope

• Use high-quality wire rope cutters to ensure a clean, non-frayed cut.
• If the ends fray, use tape around the cut area before cutting.

Step 3: Insert the Wire Rope into the Ferrule

For a Loop End:

1. Slide the ferrule (sleeve) onto the wire rope.
2. Insert the end of the wire rope through the thimble (if using).
3. Pass the end of the wire rope back through the ferrule, forming a loop.
4. Adjust the loop size before crimping.
5. Ensure that both ends sit parallel inside the ferrule.

For an End Stop:

1. Slide the end stop onto the wire rope.
2. Push the wire rope in fully so it reaches the end of the fitting.

Step 4: Position the Ferrule or End Stop for Crimping

• For a ferrule: Position the ferrule close to the thimble, leaving a small gap to prevent crushing the loop.
• For an end stop: Ensure the wire is fully seated in the end stop.

Step 5: Crimp the Ferrule or End Stop

• Use the correct crimping/swaging tool for your ferrule type.
• For a hand swager:
  1. Place the ferrule or end stop in the correct die size of the swager.
  2. Start at one end of the ferrule and work towards the other.
  3. Apply pressure firmly; for oval ferrules, crimp multiple times (typically 3 to 5 crimps).
• For hydraulic swaging:
  • Align the ferrule in the hydraulic tool’s die.
  • Activate the hydraulic press to achieve the required compression.

👉 Tip: The ferrule should be compressed evenly without deforming the wire rope inside.

Step 6: Inspect the Connection

• Check for a uniform crimp – the ferrule or end stop should be compressed evenly.
• Ensure the wire rope is not damaged during crimping.
• For a looped end, check the thimble – it should sit snugly in the loop without excessive space.

Step 7: Perform a Strength Test

• If possible, pull-test the connection to ensure it holds securely.
• Tug on the wire rope manually or use a test load to verify the crimp’s integrity.

Key Considerations

✅ Double-check the ferrule size – undersized ferrules won’t fit, and oversized ferrules won’t grip properly.
✅ Choose the correct tool – a hydraulic crimper is best for heavy-duty applications, while a hand swager is sufficient for smaller jobs.
✅ Use a go/no-go gauge (if available) to verify proper crimping.
✅ For critical applications, consider zinc pouring or using mechanical swaged fittings instead of ferrules for maximum security.