Wow
Hi there,
Let's start with those Norsepeople. Is this right-laid wire? If so, screwing the terminal together will tend to want to unlay the yarns. It can be moderated, if not completely prevented, with some careful filing of the yarn ends, and at times I've resorted to bending the yarns in towards the core -- gently, not exuberantly -- to help the start.
Unfortunately, even left-laid wire can deform upon assembly, in this case ending up over-laid above the wedge. But it's a much rarer problem which is why left-laid wire is much preferable to right-laid with this type of terminal.
If the yarns aren't lying fair above the wedge, they sometimes aren't lying fair below it, and that is a structural issue, so please sight down the wire, and make sure there are no proud yarns.
Sta-Loks have that little former inside, and its reason for being there is to avoid deformation during assembly; the yarns hit the former, and it stays put while the terminal rotates around it, so the yarns go straight into their bend without wanting to lean to either side. In practice this works better with left-laid wire than right-laid, but both are generally okay.
The wedge, though, because the yarns aren't far enough past it to lay back up and thus trap it, needs to be controlled to keep it from popping off. Much depends on the diameter of the core, as this determines how well the wedge fits. Hence the recourse to super glue and crimping. You can accomplish the same thing with skill, but it is tricky, and usually not required. In any event, violent twisting action should not be part of the equation, because that can lead to things like nicked/deformed/galled yarns, as well as deformation of the standing part.
Your rigger got things to look right, but the means he employed -- forcing the terminal into submission -- by definition were not right, because these terminals shouldn't require that kind of force.
This is not to say that you have a damaged rig, but I would recommend a very close look before calling it good. Maybe by a nice, placid rigger.
Fair leads,
Brion Toss
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