How is 7x19 wire leaded into bronze turnbuckle?

[TomHaven12]

I am rigging stays and need to know the proper technique for leading 7x19 wire into a bronze turnbuckle. Regular solder? actual lead? silver solder???

Would the process be similar to sweating copper water pipe?

[Nicholas Carey]

Normally it's either

spliced
swaged (e.g., Nicropress (http://www.nicopress.com/))
swageless fitting (e.g., Sta-Lok, Norseman)But maybe I'm missing something.

[Gold Rock]

Yeah, you're not entirely clear, cuz one doesn't attach wire to a turnbuckle at all. The wire is fixed to/around some type of terminal fitting which is then connected to the turnbuckle's own specific connective fitting. Nonetheless, we think we get your drift. Perhaps you're thinking of a poured socket type fitting? If so, the traditional encapsulating media is zinc, not lead.

[paladin]

I would assume you are speaking of Castloks......and as above..molten zinc.....Sta-loks or Norseman fittings are SOoooo much better..

[Andrew Craig-Bennett]

What Chuck says (as usual!)

No heat, less mess, same strength.

"Spelter sockets" are seldom used for anything except very big wires, like long distance tugs' towing wires, now.

[TomHaven12]

Do these photos help?
.

http://www.testrong.com/havenbuilders/myhaven/IMG_0824a.jpg
http://www.testrong.com/havenbuilders/myhaven/IMG_0825a.jpg
.
Are both parts assembled, heated, and then lead (Zinc?) melted onto the joint, as when joining copper water pipe?

[JimConlin]

Those are swage terminals. See your friendly local rigger.

[Gold Rock]

Jim's got it. Those are swage fittings. They're to be inserted into a device that uniformly squishes that tubular bit in your hand around the wire which you previously inserted into same.

[Andrew Craig-Bennett]

Yup; swage terminals.

Your local rigger has the machine for squishing them onto the wire. No other way to do it.

[George Ray]

Good Idea: Solid lo-tech, cheap and fairly easy. Still widely used, except for recreational market. A very quick look only show socket sizes down to 1/4" wire. Zinc & Epoxy are the two commonly referanced socket filler materials. It is admittadly falling out of favor because it requires knowedge and understanding and presents some toxic/safety issues.

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Website in UK:
I have to confess that I have not seen a poured socket used on a boats rigging for at least 10 years, though they are still used industrially. They consist of a fork or eye end attached to a hollow conical tube. The wire is inserted into the tube, which is then filled with molten zinc and allowed to cool. The snag with these are that it is not terribly easy to keep the kit needed to do these ends on site; the good bit is that they can be used with galvanised wire, which swaged and swageless cannot.
http://www.classicmarine.co.uk/Articles/standing_rigging.htm

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Militart Training Manual online:
http://www.tpub.com/content/engine/14081/css/14081_324.htm
Swage socket, cappel socket, and zinc (spelter) socket wire rope end connections all provide 100 percent of the breaking strength of the wire rope when properly made

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http://www.metal-mart.com/Dictionary/dictlets.htm#I59
SPELTER
(Prime Western Specter). A low-grade of Virgin Zinc containing approximately 98% Zinc used in Galvanizing processes.

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USCG: discontinues poured socket for life boat wire falls, because they are done improperly and are misunderstood, not because they are a substandard technology.

http://www.uscg.mil/HQ/G-M/NVIC/2_80/n2-80.pdf

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Aircraft carrier arresting gear discontinues poured sockets:
"The current process, which requires the sailor to pour molten zinc into the socket terminal, is toxic, hazardous and time consuming."
http://www.dodsbir.net/sitis/archives_display_topic.asp?Bookmark=29007

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http://www.gatorsupply.com/spelter.htm
http://www.gatorsupply.com/p52top.jpg
Caution: When attaching spelter sockets to wire rope it is extremely important to follow recommended procedures, such as outlined by the Wire Rope Technical Board. Proper brooming and cleaning of wire rope is important. If resin is used, follow resin manufacturer's specific installation instructions.

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http://www.industrialrope.com/closedwr.html
Molten zinc is the standard socketing material, however, an epoxy socketing material can be specified. Both have the same Rated Capacity.

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http://www.feeneywire.com/hardware/speltersockets.html
Open Spelter socket
Meets Federal Spec: RR-S0550D, Type A

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http://www.wrca.com/rs_custom_socket.html
Spelter Socket: Molten zinc is the standard socketing material, however, an epoxy socketing material can be specified. Both have the same Rated Capacity.

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