Little Bill is 100% correct on this one.
No matter how well planned or engineered, a design is useless unless properly implemented.
In my article, I specified a few issues that must be recognized to insure proper function of the swaging system.
1) The tube to be swaged MUST protrude at least 1/32 inch on each side of the swaging tool jaws, as shown in the first picture.
2) The inside of the tube MUST be chamfered as shown in the second picture. This will prevent a sharp edge from biting into the cable and causing the aforementioned riser, as shown in the last picture.
This technique insures that the swage will not come out to the end and cause the riser.
Regarding the cost – the tools shown below are indeed expensive but, in my opinion well worth it. I would investigate having a few people “chip in” and buy them – spreads the financial pain a bit.
Both tools are available from
www.savacable.com, the swaging tool is T-185 and the cutter is C07.
Hope this helps - Bob Z.