Nicopress oval sleeves - copper, tin plated, or zinc plated?

Forums: 

From: John Cooper <snopercod [at] comporium.net>
Sender: <marv [at] lancaironline.net>
Subject: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Sun, 20 Jul 2014 08:26:08 -0400
To: <lml [at] lancaironline.net>

Since one of my Nicopress sleeves failed, I've learned more than I
want to know about these things. Nicopress recommends using the 428
series tin-plated sleeves on stainless steel
cable, but Lancair sells the 18 series plain copper sleeves.
Aircraft Spruce doesn't sell the tin-plated sleeves in America (they
do in Europe), but instead they sell the 28 series zinc-plated
and the 18 series plain copper sleeves. The only
company in America that I can find who sells the Nicopress
tin-plated sleeves is VER, and they have a $50 minimum
order so I would have to buy 200 sleeves. Grainger sells some off
brand tin-plated sleeves made in China. Do I really want to use
those? I don't think so. The copper alloy is crucial to the
longevity of the crimp, I think, and who knows what I would be
getting. McMaster-Carr sells some "TIN-Plated Copper Oval
Compression Sleeve for 3/32" Rope Diameter, 3/8" Sleeve Length". No
Country of origin listed, but they do say "All sleeves meet MIL-STD
51844". Unfortunately, the length before crimping is listed at 3/8"
rather than the 7/16" that MS51844 Rev. E calls for. So I'm
flummoxed.



Does anyone know of a source for the authentic, Mil spec. Nicopress
428-3-VG tin plated oval crimp sleeves for 3/32"
stainless steel cable?



OTOH, does the plating really matter? Is galvanic corrosion really a
concern in the foot-well? I noted that my failed copper crimp sleeve
had blue copper corrosion all over it. Sure, I used the wrong tool
originally, but could corrosion have been a factor in the failure?
Possibly, according to this Kitplane article The
Big Squeeze
. It's a great article from 2013 answers a lot of
my questions, including:


Why three types? The idea is to match sleeve
and cable finish for the least damaging galvanic potential between
components. While any copper sleeve choice will initially
withstand the rated load when installed on either galvanized or
stainless cable, corrosion will weaken the mechanical joint given
time, the wrong environment, and the wrong combination of
materials. The specifications are quite specific. Bare copper or
zinc-plated sleeves are used on galvanized carbon steel cable. Tin-plated
sleeves (or as noted previously, stainless steel sleeves) are
used on stainless cable. There are no exceptions.



and...

Zinc-plated sleeves on stainless
cable has been an obsolete recommendation
for more
than 40 years.


Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: Jeff Edwards <vtailjeff [at] aol.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Mon, 21 Jul 2014 07:25:46 -0400
To: <lml [at] lancaironline.net>
John,

Galvanic corrosion occurs when two dissimilar metals on the anode cathode scale are put together. So yes it is a concern if you have the wrong sleeve.

Jeff

Sent from my iPad

On Jul 20, 2014, at 7:26 AM, John Cooper <snopercod [at] comporium.net

> wrote:

Since one of my Nicopress sleeves failed, I've learned more than I
want to know about these things. Nicopress recommends using the 428
series tin-plated sleeves on stainless steel
cable, but Lancair sells the 18 series plain copper sleeves.
Aircraft Spruce doesn't sell the tin-plated sleeves in America (they
do in Europe), but instead they sell the 28 series zinc-plated
and the 18 series plain copper sleeves. The only
company in America that I can find who sells the Nicopress
tin-plated sleeves is VER, and they have a $50 minimum
order so I would have to buy 200 sleeves. Grainger sells some off
brand tin-plated sleeves made in China. Do I really want to use
those? I don't think so. The copper alloy is crucial to the
longevity of the crimp, I think, and who knows what I would be
getting. McMaster-Carr sells some "TIN-Plated Copper Oval
Compression Sleeve for 3/32" Rope Diameter, 3/8" Sleeve Length". No
Country of origin listed, but they do say "All sleeves meet MIL-STD
51844". Unfortunately, the length before crimping is listed at 3/8"
rather than the 7/16" that MS51844 Rev. E calls for. So I'm
flummoxed.



Does anyone know of a source for the authentic, Mil spec. Nicopress
428-3-VG tin plated oval crimp sleeves for 3/32"
stainless steel cable?



OTOH, does the plating really matter? Is galvanic corrosion really a
concern in the foot-well? I noted that my failed copper crimp sleeve
had blue copper corrosion all over it. Sure, I used the wrong tool
originally, but could corrosion have been a factor in the failure?
Possibly, according to this Kitplane article The
Big Squeeze
. It's a great article from 2013 answers a lot of
my questions, including:


Why three types? The idea is to match sleeve
and cable finish for the least damaging galvanic potential between
components. While any copper sleeve choice will initially
withstand the rated load when installed on either galvanized or
stainless cable, corrosion will weaken the mechanical joint given
time, the wrong environment, and the wrong combination of
materials. The specifications are quite specific. Bare copper or
zinc-plated sleeves are used on galvanized carbon steel cable. Tin-plated
sleeves (or as noted previously, stainless steel sleeves) are
used on stainless cable. There are no exceptions.



and...

Zinc-plated sleeves on stainless
cable has been an obsolete recommendation
for more
than 40 years.


Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: Guy Buchanan <gebuchanan [at] cox.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Mon, 21 Jul 2014 07:26:17 -0400
To: <lml [at] lancaironline.net>
Both of these are kind of funny, since
zinc plated sleeves have been used in the marine industry for at
least the last 40 years, and they hold up pretty (read: very) well
in a salt water environment, up to the strength of stainless 7x19
cable.


Guy Buchanan

Ramona, CA

Kitfox IV-1200 / 912-S / Warp 3cs / 500 hrs. and grounded

Now a glider pilot, too.



On 7/20/2014 5:26 AM, John Cooper wrote:

list-6987270 [at] logan.com" rel="noopener" type="cite">

or zinc-plated sleeves are used on galvanized carbon steel cable.
Tin-plated sleeves (or as noted previously, stainless
steel sleeves) are used on stainless cable. There are no
exceptions.


and...

Zinc-plated sleeves on stainless
cable has been an obsolete recommendation
for
more than 40 years.



Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: John Cooper <snopercod [at] comporium.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Mon, 21 Jul 2014 18:27:50 -0400
To: <lml [at] lancaironline.net>

Thanks for the data point, Gary. Certainly the marine industry is a
much harsher corrosion environment than the inside of an airplane.
There's so much conflicting information out there that it's hard to
know whom to believe, but I can tell you one thing: Over the last
few days I've learned a lot more about Nicopress sleeves than I
really cared to know.



With a magnifying hood, I looked down the barrel of the copper
sleeve that failed on my airplane and there was zero corrosion in
there, nor did I see any on the cable end that pulled through. So I
am convinced that my particular failure had nothing to do with
corrosion, but was solely due to my using the wrong crimp tool. I am
also convinced that plain copper sleeves work just fine with the SS
cables. Several knowledgeable people have advised me "The plating
just doesn't matter", and they're probably right.



There may be considerations other than corrosion due to dissimilar
metals in contact with each other, but I have to think that the
purpose of using one plating or another is to prevent galvanic
(electrochemical) corrosion. I'm definitely not an expert in that
field. but I do have a friend who is a retired chemical engineer.
The two of us went over the Galvanic
Table
and agreed that bare copper is the most compatible to
non-passivated 304 (active) stainless steel, followed closely by tin
plate. The zinc plate was very anodic and just looking at that
chart, one would say zinc wasn't a good choice. Go figure...



Yesterday, based upon our research, I was all set to just use the
plain copper crimp sleeves as sold by Lancair. But then I read FAR
43.13(a) (methods, techniques, and practices), which states:


    …each person performing maintenance, alteration,
or preventive maintenance on an aircraft, engine, propeller, or
appliance shall use the methods, techniques, and practices prescribed
in the current manufacturer's maintenance manual or
Instructions
for Continued Airworthiness prepared
by its manufacturer, or other methods, techniques, or practices
acceptable to the Administrator….



The manufacturer - Nicopress - specifies tin-plated sleeves for use
on stainless cables. So does Mil-Spec MS51844E (SLEEVE, SWAGING-WIRE
ROPE). So  does Kitplanes magazine. So does JR Clancy - a rigging
company. So although theoretically the plain copper may be just as
good or better, I have to go with what the "authorities" recommend.
I guess my years working for NASA ruined me...



So I just bit the bullet and ordered 250 (minimum order) of the
428-3-VG Nicopress tin plated sleeves and am having them shipped
from Burbank via UPS 2nd Day Air. Cost: $57 for the parts and $40
for the shipping. Sigh...



I suppose I can sell the unused ones on eBay or something...



Now that I'm in possession of the proper crimp tool that Tom loaned
me, as well as the Go gauge, I've made a couple of test crimps and
they came out just fine. So I'm moving on to some other puzzle
now...



--John



P.S. Another thing I discovered while researching this is that the
FAA is frowning upon the use of stainless control cables at all.


From: Guy Buchanan
gebuchanan [at] cox.net (<>)

Sender: marv [at] lancaironline.net (<>)

Subject: Re: [LML] Nicopress oval
sleeves - copper, tin plated, or zinc plated?
Date: Mon, 21 Jul 2014 07:26:17
-0400
To: lml [at] lancaironline.net

Both of these are kind of funny,
since zinc plated sleeves have been used in the marine industry
for at least the last 40 years, and they hold up pretty (read:
very) well in a salt water environment, up to the strength of
stainless 7x19 cable.



Guy Buchanan

Ramona, CA

Kitfox IV-1200 / 912-S / Warp 3cs / 500 hrs. and grounded

Now a glider pilot, too.



On 7/20/2014 5:26 AM, John Cooper wrote:

or zinc-plated sleeves are used on galvanized carbon steel cable.
Tin-plated sleeves (or as noted previously, stainless
steel sleeves) are used on stainless cable. There are no
exceptions.


and...

Zinc-plated sleeves on stainless
cable has been an obsolete recommendation
for
more than 40 years.



Image


TextHeaders.gif


Image


TextLetter.gif

Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: Guy Buchanan <gebuchanan [at] cox.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Tue, 22 Jul 2014 07:22:02 -0400
To: <lml [at] lancaironline.net>
It is true that SS cables work harden
and fish-hook much quicker than galvanized. That's why you saw a
lot of galvanized running rigging on race yachts in the old days.
(Now days it's all synthetic.) I think, however, that unless
you're running silly high tensions in your control cables, or
silly small sheaves, you won't have a problem with stainless,
particularly 3/32" 7x19.


Guy
Buchanan

Assistant Scoutmaster –
Troop 680

760.809.6145

gebuchanan [at] cox.net

 

www.troop680.org

 





On 7/21/2014 3:27 PM, John Cooper wrote:

list-6992135 [at] logan.com" rel="noopener" type="cite">P.S.
Another thing I discovered while researching this is that the FAA
is frowning upon the use of stainless control cables at all.


Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: Chris Zavatson <chris_zavatson [at] yahoo.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Tue, 22 Jul 2014 13:23:58 -0400
To: <lml [at] lancaironline.net>
John,
Technically you are still in compliance with the regs if you use uncoated copper sleeves.
In the applicability section of 43.1 it states"  (b)This part does not apply
to-  (1)Any aircraft for which the FAA has issued an experimental certificate, unless the FAA has previously issued a different kind of certificate for that aircraft, or..........It goes on to list a few other non-applicable exceptions.

In general, it is wise to follow a manufacturers recommendation.  Typically they will have the most experience and knowledge pertaining to their product.  Sometimes other factors cause their recommendation to deviate from the best technical solution however - legal and liability concerns or financial considerations for example.   In the final analysis, if there is a solution that is as good or
perhaps even better than that provided by a manufacturer, there is nothing preventing its implementation in our aircraft.  

Chris Zavatson
N91CZ
360 std

On Monday, July 21, 2014 3:27 PM, John Cooper <snopercod [at] comporium.net

> wrote:




Thanks for the data point, Gary. Certainly the marine industry is a
much harsher corrosion environment than the inside of an airplane.
There's so much conflicting information out there that it's hard to
know whom to believe, but I can tell you one thing: Over the last
few days I've learned a lot more about Nicopress sleeves than I
really cared to know.



With a magnifying hood, I looked down the barrel of the copper
sleeve that failed on my airplane and there was zero corrosion in
there, nor did I see any on the cable end that pulled through. So I
am convinced that my particular failure had nothing to do with
corrosion, but was solely due to my using the wrong crimp tool. I am
also convinced that plain copper sleeves work just fine with the SS
cables. Several knowledgeable people have advised me "The plating
just doesn't matter", and they're probably right.



There may be considerations other than corrosion due to dissimilar
metals in contact with each other, but I have to think that the
purpose of using one plating or another is to prevent galvanic
(electrochemical) corrosion. I'm definitely not an expert in that
field. but I do have a friend who is a retired chemical engineer.
The two of us went over the Galvanic
Table
and agreed that bare copper is the most compatible to
non-passivated 304 (active) stainless steel, followed closely by tin
plate. The zinc plate was very anodic and just looking at that
chart, one would say zinc wasn't a good choice. Go figure...



Yesterday, based upon our research, I was all set to just use the
plain copper crimp sleeves as sold by Lancair. But then I read FAR
43.13(a) (methods, techniques, and practices), which states:


    …each person performing maintenance, alteration,
or preventive maintenance on an aircraft, engine, propeller, or
appliance shall use the methods, techniques, and practices prescribed
in the current manufacturer's maintenance manual or
Instructions
for Continued Airworthiness prepared
by its manufacturer, or other methods, techniques, or practices
acceptable to the Administrator….



The manufacturer - Nicopress - specifies tin-plated sleeves for use
on stainless cables. So does Mil-Spec MS51844E (SLEEVE, SWAGING-WIRE
ROPE). So  does Kitplanes magazine. So does JR Clancy - a rigging
company. So although theoretically the plain copper may be just as
good or better, I have to go with what the "authorities" recommend.
I guess my years working for NASA ruined me...



So I just bit the bullet and ordered 250 (minimum order) of the
428-3-VG Nicopress tin plated sleeves and am having them shipped
from Burbank via UPS 2nd Day Air. Cost: $57 for the parts and $40
for the shipping. Sigh...



I suppose I can sell the unused ones on eBay or something...



Now that I'm in possession of the proper crimp tool that Tom loaned
me, as well as the Go gauge, I've made a couple of test crimps and
they came out just fine. So I'm moving on to some other puzzle
now...



--John



P.S. Another thing I discovered while researching this is that the
FAA is frowning upon the use of stainless control cables at all.


From: Guy Buchanan
gebuchanan [at] cox.net" target="_blank" href="mailto:gebuchanan [at] cox.net"><gebuchanan [at] cox.net>
Sender: marv [at] lancaironline.net" target="_blank" href="mailto:marv [at] lancaironline.net"><marv [at] lancaironline.net>
Subject: Re: [LML] Nicopress oval
sleeves - copper, tin plated, or zinc plated?
Date: Mon, 21 Jul 2014 07:26:17
-0400
To: lml [at] lancaironline.net" target="_blank" href="mailto:lml [at] lancaironline.net">lml [at] lancaironline.net
/files/LML/70416-02-01-R/1.3872578752 [at] web161203.mail.bf1.yahoo.com" sandbox="" alt="Message Header" border="0">



/files/LML/70416-02-01-R/2.3872578753 [at] web161203.mail.bf1.yahoo.com" sandbox="" alt="Undecoded Message" border="0">
Both of these are kind of funny,
since zinc plated sleeves have been used in the marine industry
for at least the last 40 years, and they hold up pretty (read:
very) well in a salt water environment, up to the strength of
stainless 7x19 cable.



Guy Buchanan

Ramona, CA

Kitfox IV-1200 / 912-S / Warp 3cs / 500 hrs. and grounded

Now a glider pilot, too.



On 7/20/2014 5:26 AM, John Cooper wrote:

or zinc-plated sleeves are used on galvanized carbon steel cable.
Tin-plated sleeves (or as noted previously, stainless
steel sleeves) are used on stainless cable. There are no
exceptions.


and...

Zinc-plated sleeves on stainless
cable has been an obsolete recommendation
for
more than 40 years.





Image


TextHeaders.gif


Image


TextLetter.gif

Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: John Cooper <snopercod [at] comporium.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Fri, 25 Jul 2014 07:37:43 -0400
To: <lml [at] lancaironline.net>

I can't say what's right or wrong regarding these Nicopress sleeves;
All I can do is relate what I chose to do. I used the zinc-plated
428-3-VG oval sleeves, and I decided to use two of them on
each cable as pull-through insurance. Also, I had planned to reverse
the cable so the factory end was at the pedals, but I changed my
mind. The main reason was that the loop of cable wrapped around the
AN111 thimble was captive up front, but not captive at the rudder; I
would have had to use an area washer on top of the AN111 thimble and
I thought that would look like hell. I am convinced that I can
adequately inspect these Nicopress crimps in the footwell with a
mirror and a flashlight.



A couple of recommendations: When using two sleeves, be careful to
get them aligned before crimping the second one. It's kind of hard
with that big crimping tool, but it's something to watch for. My
second crimp was ever-so-slightly off so there's a small bend in the
cable (visible in the photo below).



The other tip is that the sharp end of the cut off cable (I used a
Dremel with a cutoff wheel) will cut right through the heat shrink
tubing. On the second one, I wrapped about 1" of electrical tape
over the two cables to secure the loose strands and sharp edges.
Then the heat shrink tubing slid nicely over the two cables.



Obviously, you'll want to gauge each crimp with the GO gauge.



/files/LML/70440-02-01-R/part1.03020909.04050504 [at] comporium.net" sandbox="" width="877" height="585">


Image


Transformed_Lancair new rudder cables 004.JPG

Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: Bill Harrelson <n5zq [at] verizon.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Fri, 25 Jul 2014 09:57:09 -0400
To: <lml [at] lancaironline.net>
John,
 
That seems like an awfully tight cable bend
around that AN3 bolt. Should you have used a thimble?
 
Bill
 

Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: John Cooper <snopercod [at] comporium.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Fri, 25 Jul 2014 13:45:13 -0400
To: <lml [at] lancaironline.net>

Bill--



Ummmm....I did use a thimble - the AN111 Cable
Bushing
called for in the 235 plans. I agree that it's a tight
bend but I didn't feel like having something with a larger radius
custom machined. What did you use on your IV?



--John



From:     "Bill Harrelson" n5zq [at] verizon.net (<>)



Sender:     marv [at] lancaironline.net (<>)



Subject:     Re: [LML] Re: Nicopress oval sleeves - copper, tin
plated, or zinc plated?

Date:     Fri, 25 Jul 2014 09:57:09 -0400

To:     lml [at] lancaironline.net





John,

 

That seems like an awfully tight cable bend around that AN3 bolt.
Should you have used a thimble?

 

Bill

 

Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: Bill Harrelson <n5zq [at] verizon.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Fri, 25 Jul 2014 20:27:35 -0400
To: <lml [at] lancaironline.net>
Ah, ok, sorry John. I didn’t see it in the photo.
I thought that you had just wrapped the cable around the bolt. As Rosanne
Rosanadana used to say,... never mind.
 
Bill
 
 
 
 
 
 
Bill--

Ummmm....I
did use a thimble - the AN111 Cable
Bushing
called for in the 235 plans. I agree that it's a tight bend but I
didn't feel like having something with a larger radius custom machined. What did
you use on your IV?

--John

 

John,
 
That seems like an awfully tight cable bend around
that AN3 bolt. Should you have used a
thimble?
 
Bill
 

Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: Mark Sletten <mwsletten [at] gmail.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Mon, 28 Jul 2014 05:40:24 -0400
To: <lml [at] lancaironline.net>
Bill, we must be getting old; I made the same mistake last week! It was Gilda Radner who portrayed the character Rosanne Rosannadanna, but it was her other character, elderly (!) and hard of hearing Emily Litella who was famous for her malapropisms.

God help us... and nevermind...

--Mark


Bill said--

Ah, ok, sorry John. I didn’t see it in the photo. I thought that you had just wrapped the cable around the bolt. As Rosanne Rosanadana used to say,... never mind.
 



On Fri, Jul 25, 2014 at 7:27 PM, Bill Harrelson <n5zq [at] verizon.net

>
wrote:
Ah, ok, sorry John. I didn’t see it in the photo.
I thought that you had just wrapped the cable around the bolt. As Rosanne
Rosanadana used to say,... never mind.
 
Bill
 
 
 
 
 
 
Bill--

Ummmm....I
did use a thimble - the AN111 Cable
Bushing
called for in the 235 plans. I agree that it's a tight bend but I
didn't feel like having something with a larger radius custom machined. What did
you use on your IV?

--John

 

John,
 
That seems like an awfully tight cable bend around
that AN3 bolt. Should you have used a
thimble?
 
Bill
 


Nicopress oval sleeves - copper, tin plated, or zinc plated?

From: John Cooper <snopercod [at] comporium.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: Nicopress oval sleeves - copper, tin plated, or zinc plated?
Date: Mon, 28 Jul 2014 05:43:01 -0400
To: <lml [at] lancaironline.net>

Bill--



No problem. Thanks for watching out for me! I've been known to do
stupid things in the past (like use the wrong crimping tool).



Can anyone tell me what the IVs or Legacies use in place of the
too-small AN111 "Cable Bushing" at the rudder pedals?



--John



P.S. I have the surplus tin-plated nicopress 428-3-VG sleeves for
sale on eBay if anybody is interested. $8 for ten with free
shipping.


From: "Bill Harrelson"
n5zq [at] verizon.net (<>)

Sender: marv [at] lancaironline.net (<>)

Subject: Re: [LML] Re: Nicopress
oval sleeves - copper, tin plated, or zinc plated?
Date: Fri, 25 Jul 2014 20:27:35
-0400
To: lml [at] lancaironline.net

Ah, ok, sorry John. I didn’t see it
in the photo. I thought that you had just wrapped the cable
around the bolt. As Rosanne Rosanadana used to say,... never
mind.
 
Bill



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