Swageless Fittings

The tools you need are:

• Life Calk.
• Paper towels.
• 2 adjustable wrenches.
• Fine tooth hack saw blade.
• Loctite #242 Blue or #241 Blue or Loctite #277 Red

1. CUT THE WIRE

If you are using a hacksaw, a new quality blade is highly recommended.

You want the cut to be square without protruding wires.

2. UNRAVEL THE WIRE

Slide the end over the wire and then unravel the outer strands (one strand at a time) 2-3 inches exposing the center core and slide the wedge over the center core.

Your wire should look like the photo to the right.

3. REPOSITION THE OUTER STRANDS

Twist the wire so that it reforms around the wedge. Insure that the strands protrude 1/8 inch (2-3mm) from the eye of the wedge.

4. PUSH THE SOCKET OVER THE WIRE

Individual wires should not over lap! Make sure the wires are evenly arranged around the wedge.
Before you push make sure the strands are evenly spaced around the wedge. Do not let a strand slip into the wedge slot of the wedge.

7x19 wedge	1x19 wedge

Tip: Push the fitting towards the end of the wire while repositioning the wire.

Important Tip: Put a couple of drops of Loctite on the starting threads when first assembling the terminal. This Loctite will act as a lubricant and will insure that the threads will not gall. This Loctite will also insure that the terminal will not loosen after the final assembly. The Loctite will not setup until the terminal is closed as it is anaerobic. (Only sets up in the absence of air.)

5. THE FORMING PROCESS

The initial forming process begins when you begin screwing the parts together.

Remember, do not over tighten and, when you begin to bottom out... Stop!

Unscrew the fitting and check to make sure the wires are evenly formed around the wedge. The wires should be evenly arranged, not overlapping and the slot must not have a trapped wire. If you see a wire inside the slot, pry it out.

The wedge must compress. Consequently, the slot must be clear for tightening.
If the wires have been cut squarely, the wire will form perfectly!

6. THE FINAL ASSEMBLY

Fill the cavity of the terminal's body about ½ full of Boat Life and place a few drops of the Loctite on the threads. Reassemble the fitting and tighten to the point of bottoming out.

Do not over tighten!

Over-tightening will damage the threads and wire. Over-tightening may render the terminal impossible to reuse at a later date.

RIGGER NOTES

1. The Loctite secures the fitting.
2. Wipe off any excess Loctite and caulking and the project is finished!
3. Some threads will remain visible. The fitting is designed to accept a range of wires sizes with the use of an appropriate wedge.