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	WPI Technical Theatre Handbook: Thimbles, Wire Rope Clips, and Swages
	Thimbles, Wire Rope Clips, and Swages Figure 4.3: Correct and incorrect methods for using clips and thimbles on wire rope. The saddle of the clip rests against the ``live'' portion of the wire rope while the U-bolt rests on the short, ``dead'' portion of the wire rope. Using clips improperly severely weakens the connection, making it unsafe. Remember: never saddle a dead horse. When working with wire rope, it is extremely important that several guidelines are followed with regards to termination. Any time the wire rope needs to be attached to a hang point that would cause the cable to sharply bend, a device called a thimble must be used. Thimbles simply guide the cable into a natural curve shape and offer a degree of protection to the cable in the loop. To secure the end of the rope, wire rope U-clips are used. These clips provide an effective means for terminating cables, but must be used properly to be fully effective. Figure 4.3 shows correct and incorrect methods for applying these clips. The correct sequence for applying U-clips to a piece of wire rope are described below: Turn back the appropriate amount of cable from the end of the piece being worked on. This amount varies with the diameter of the wire rope, but is typically from 12 to 18 inches. Apply the first clip nearest the very end of the cable. Always leave a couple of inches of extra cable beyond the clip. Be sure to apply the clip properly -- the U-bolt goes around the dead end of the cable, while the saddle goes around the live end. Tighten the nuts on the U-clip evenly, and to the torque recommended by the clip manufacturers. If a thimble is being used, insert it into the loop, and then apply the second clip in the same fashion as the first, but only finger tighten the nuts. Apply additional clips evenly between the first two clips. Two clips are usually sufficient for wire rope under 1/2 inch, but three are often used for safety. Wire rope of diameter 3/4 inch or greater requires four or more clips. Tighten all clips to the recommended torque. Apply the load and re-tighten the clips. This re-tightening is important, as wire rope tends to shrink in diameter as load is applied. Another method for securing the ends of wire rope is through the use of swages, or nicopress sleeves. Small metal sleeves are pressed on to the wire rope with a special tool. These sleeves are permanent, but act much in the same way that clips do. When properly applied, swages can hold the full rated working load of the cable they are attached to. Use of information in this document implies understanding and agreement with the copyright and terms of use. Specifically, no warranty is expressed or implied regarding the accuracy of the information contained within. YOU USE THIS INFORMATION AT YOUR OWN RISK. All trademarks are property of their respective owners. You must obtain permission from the author before using the contents of The Handbook for anything other than private use.	Table of Contents [Whole book in PDF 5.3MB] Contents Introduction Goals Sources Methods Conclusions Costumes Introduction Procurement Fabrics Color Patterns Fitting Rehearsal Clothing Design How to Begin Color Practicality Documents The Set Introduction Set Pieces Platforms Flats Stairs Rakes Other Structures Floor Coverings Construction Materials Tools Finishing Painting Types of Paint Mixing Paints Applying Paint Draperies Design How to Begin Documents Computer-Aided Design A Typical Set Construction at WPI Rigging Introduction Common Rigging Hardware Rope Wire Rope Thimbles, Wire Rope Clips, and Swages Shackles, Turnbuckles and Hooks Chain & Rapid Links Slings Fly Methods Non-Counterweighted Pulley Systems Counterweighted Fly Systems Lifts Chain Motors Flying Set Pieces Lighting Introduction Lighting Instruments Scoops Cyclorama Lights Parabolic Reflector Cans Fresnel Spotlights Ellipsoidal Reflector Spotlights Automated Instruments Color Color Theory Primary, Secondary and Complementary Colors of Light Light Mixing Practical Use of Color Glass, Gelatine and Plastics Dichroic Color Filters Patterns Dimmers Dimmer History Cables and Connectors Lighting Boards Control Design Washes Specials Cyclorama Lighting Color Lighting Angle Simulating Exteriors Lighting Design Paperwork Shop Order Instrument Plots Focus Sheets Computer-Aided Lighting Design A Typical Lighting Hang at WPI Audio Introduction Input Microphones Converting Sound to Electricity Directionality Analog Tape Digital Audio Tape (DAT) Compact Disc (CD) Mini-Disc (MD) Digital Samplers Computer Sound Cards Mixing Boards Signal Processing Equipment Equalizers Compressors and Limiters Noise Gates Effects Processors Output Power Amplifiers Speakers Crossovers Cabling and Connectors Line-Level Speaker-Level Automation Design Creating and Obtaining Effects Editing and Processing Effects Designing the Sound System The Input Section Signal Processing The Output Section A Typical Audio Setup at WPI Power Introduction Basic Theory Power Feeds Power Distribution Boxes Power Protection Important Considerations Special Effects Introduction Animated Costuming Smoke and Fog Pyrotechnics Acknowledgements References List of Figures Index About this document ...

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