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Walker 11-28-2016 06:55 PM

Need help, swaging die.
I am building another cable rail. This one has several hundred terminals. I have been using a small hydraulic hand held unit to swaging the terminals. It is wore out, and takes 3 passes to fully swage each terminal. The dies are also wore out.

So, looking to make a new set of dies to use on the punch end of my ironworker. I usually just weld them to the end of some steel 2x2 pieces the I mint in place of the punch.

It would be easy enough to take two pieces of heavy flat bar, drill a hole down the seam, and be done. However, I don't have access to S7, or the like without a two hour drive.

Any ideas as to common materials (springs, tools) and methods (I can forge, just out of fuel) that might work?

Walker 11-28-2016 07:02 PM

Just typing it in has spurred some ideas. I have some broken ironworker punches that are the perfect size for dies, just need to figure out how to put in the half round groove.

gimpyrobb 11-28-2016 07:10 PM

Any pics of the old components?

Walker 11-28-2016 09:44 PM

1 Attachment(s)
Just a cheap hydraulic press with hex dies.

1/4" half round would work just fine.

digr 11-28-2016 09:50 PM

I don't have access to S7 What does this mean S7? Why can't you do the flat bar trick?

milomilo 11-28-2016 10:04 PM

How much tension on the cable do you expect? How much pressure did the old tool have?

Walker 11-28-2016 10:22 PM

I don't think the punches will work, just not enough clearance at the punch holder.

I did stumble across an old set of shear blades that would work. If I can figure out a way to semi accurately grind a 1/4" groove with an angle grinder it would work.
Maybe clamping a couple flat bars on each side of the groove with some sort of depth stop on the grinder. May have to sleep on it.

Walker 11-28-2016 10:28 PM

Digr, the S7 is a hardenable steel, not sure how well mild would hold up. Since I do a couple rails a year it would be nice to have a tool that will hold up.

The old tool had 20-40 tons iirc, but they were Chinese tons, not American tons, so I don't know how hard it would really squeeze.

Norm W 11-28-2016 10:31 PM

How about grinding the desired size "hole" in the blades of a large set of bolt cutters? You might have to swage in a couple of sections as it wouldn't be a wide set of jaws.

Walker 11-28-2016 10:48 PM

Norm, when you have hundreds to do it gets old fast doing them by hand. I can stomp a peddle that many times without thinking twice.

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