Oh My - what a drama - new swaging failure

[ribbony]

We have been taking our new wire and fittings, cut and ready to swage to a rigger to get them swaged. It has been a challengine time to do it one or two wires at a time while the mast was up on the boat, on the mooring, but we got there. Then the rigger drops a bombshell. The swaging press has not been compressing enough and he had a recent fitting fail in service (not ours) and told us not to use our rig until he gets back to us. He is having some destructive testing done to assess structual integrity.

We took the initiative and got on to the manufacturer of the swaged products who replied to our email promptly. They gave us the sizes for the swaged fittings after swaging. I checked our against this. The specification for 5/16" wire is a swaged diameter of 14.30mm (tolerance +0.00 & -0.20), our fittings measure 14.75, 14.90, 14.85, 14.65, 14, 95, etc etc.

All fittings were double pass swaged and if they are swaged again that makes them 3 passes. The engineer at the manufacturer said that 3 passes was not ideal and sometimes because the metal has been compressed twice then it may not want to move (flow) much a third time and may tend to spring back.

If anyone can give us some experienced advice on this it would be much appreciated. We kinda feel that our new rig already has integrity issues and don't know where to go from here. http://briontoss.com/spartalk/images...s/confused.gif