Standing Rigging

Swageless wire-rope terminals have long been a favorite piece of rigging kit among all kinds of sailors. These terminals are inspectable, reusable, and can be assembled with simple hand tools. But for all of their acknowledged advantages, data is scarce about their mechanical efficiency. How much, if any, do they weaken the wire rope they are attached to?

During the first round of mechanical terminal testing, testers were surprised to see that wire failures were occurring at loads that were at least 10-percent lower than expected. The swaged-end fittings had been applied by a rotary swage machine, which is considered to be a very reliable way to form swaged terminals.

The most common error with poured sockets is insufficient cleaning of the wire, and/or using the wrong solvent to clean it. Even dry, stainless wire, when new, can have a residue of lubricant left over from the extrusion process. If this lubricant is not removed, it can compromise the adhesion of the wire yarns to the filler material in the socket.

All of the mechanical terminals we tested are based on the same assembly concept: The rigger opens the cover yarns, and then slides a wedge over the core yarns, near the end of the wire. The rigger closes the cover yarns over the wedge, and then, screws together the two outer parts of the terminal over the wedge, compressing the material, and thus generating friction. Simple, but like any assembly, it can be done wrong. Here are a few things to watch out for when assembling a mechanical terminal.

Standing rigging has been evolving ever since natural fiber lines were lashed, knotted, or spliced to wooden spars, and led down to crudely fashioned, iron deck hardware. The challenge has always been the transition point where the straight-line pull (tension) changes direction, creating a stress riser in the rope, wire, or rod. Today, the materials have changed, but the challenge remains the same.

Each manufacturer offers specific guidance for terminal assembly, and some do a better job than others. The following is a generic description of the assembly process using a Norseman fitting as an example. The other two fittings in our comparison, the Sta-Lok and the Hi-Mod, incorporate a third component, a crown that helps guide and hold the wire strands in place.

A couple of months ago, PS Technical Editor Ralph Naranjo disassembled a headstay that he had used aboard his Ericson 41 sloop, Wind Shadow, for nearly a decade. It was set up with Norseman fittings as terminals for 3/8-inch diameter, 1x19 stainless-steel wire that had supported a Harken roller-furling system. During disassembly, neither the wire nor the end fittings showed signs of corrosion or physical wear. And when the fittings themselves were taken apart-requiring heat to free the sealant in the terminal-the wire bundle was pristine and showed no sign of any slippage or corrosion.

Testers first task was to determine whether any of these coatings could weaken line in the near term. To do this, we formed 20-inch loops of 1/8-inch polyester braid and nylon braid, coated a 1-inch length of the loop with each of the products, and broke these in our test rig.

Its been almost 10 years since Practical Sailor weighed in specifically on mainsail track hardware. (See Practical Sailor, Feb. 1, 2005 online) At the time, we offered a summary of the products designed to manage what we termed the three Ss of mainsail handling-setting, shortening, and striking. In that article, we focused on the gear used with full-battened mainsails, which were becoming increasingly popular among a broad spectrum of sailboat owners then.

For decades, adjusting the genoa sheet leads from the cockpit was a luxury ascribed to racing sailboats. But todays cruising sailboat equipped with a roller-furling headsail also benefits from an efficient, safe means of adjusting the genoa sheets lead angle. We tested 11 genoa sheet-lead cars and tracks from the top manufacturers of sailboat deck hardware: Antal, Garhauer, Harken, Nautos, Ronstan, Schaefer, and Selden. Testers looked at the genoa-sheet controls operational efficiency, design and attributes, construction quality, and ease of installation; price and warranty were also considered.