McFarlane Specification PS118 Rev L - Redacted

Page 1
McFarlane Aviation, Inc.

Production Specification 118, Rev L
05/17/2022
REVISION LOG
Revision Changes Date Author
~ All 05/18/2017
A 8.4, 9.1.2 06/21/2017
B 1.2.2, 5A.7 07/03/2017
C 5A.6, Added Section 9.1.3 08/07/2017
D 3.3.2 & 3.3.3 12/21/2017
E 1.3, 5A.3, 5A.5, 9.1.3, 9.2 07/17/2018
F Update 1.2.2, 3.3.2 09/05/2019
G Updated 1.2.2 & 5A.5 11/26/2019
Updated Title Page, 1.2.1, 1.2.2, 1.2.3, 3.2.1, 3.2.1.1, 3.2.1.2, 3.2.1.3,
H 3.2.1.4, 3.3.1, 4, 5B.2, 9.1.1, 9.1.2, 08/11/2020
Added 3.3.4, 3.3.5, 3.3.6, 5A.8, 5B.5, 6.5, 6.6, 9.4, 9.5, 9.6
J Updated 5A.8.14 10/07/2020
Updated 1.1, 3, 3.1.1, 3.3.3, 3.3.6, 5A, 5A.8.14, 6.2, 7.1, 7.2, 9, 9.1.1,
K 9.1.2, 10, 10.1, 10.4, & Appendix I 12/03/2020
Added 3.3.7, 3.4, 6.7, 6.8, 9.7, 9.8, & Appendix II
Updated title page layout to the template rev AZ.
Updated the Revision Log to the template rev AZ.
L Section 3.3.4: Update inspection to have receiving send a sample to 5/17/2022 MPG
as we do not have Color Matching samples. This is
performed by
CONFIDENTIAL AND PROPRIETARY

This document contains confidential and proprietary information and may not be
disclosed without the express written consent of McFarlane Aviation Products.
Page 2
05/17/2022
Table of Contents
1. MATERIAL SPECIFICATIONS AND PROCUREMENT REQUIREMENTS ............................................ 3
2. APPLICABLE DATA ................................................................................................................................. 6
3. INCOMING INSPECTIONS ....................................................................................................................... 6
4. STORAGE REQUIREMENTS ................................................................................................................. 12
5A. MANUFACTURING METHODS AND CONTROLS .............................................................................. 12
5B. PERSONNEL TRAINING ...................................................................................................................... 23
6. IN-PROCESS INSPECTIONS .................................................................................................................. 24
7. TOOL CALIBRATION ............................................................................................................................. 27
8. IDENTIFICATION AND PACKAGING REQUIREMENTS ...................................................................... 28
9. FINAL INSPECTIONS ............................................................................................................................. 29
10. RETURN HANDLING INSPECTIONS ................................................................................................... 32
APPENDIX IV: SWAGING TIME, PRESSURE, AND DIMENSIONAL DATA FOR SWAGED TERMINALS USING
AT520D CABLE SWAGER ................................................................................................................... 33

Page 3
05/17/2022
Preface
This production specification is designed to supplement the McFarlane Aviation, Inc. Quality
Assurance Manual and Production Specification No. 4 and 8 in specific procedures, controls,
inspections, and identifications for production of aircraft control cable assemblies or
subassemblies to Military Specifications, National Aerospace Standards, Airforce-Navy
Aeronautical Design Standards or custom terminals as required by the McFarlane Aviation,
Inc. FAA Approved Design Data and Drawings.
1. Material Specifications and Procurement Requirements

1.1 General Requirements
All Purchase orders must meet the requirements of Section 8.4 of the McFarlane Aviation,
Inc. Quality Assurance Manual.
All materials used must conform to the applicable McFarlane FAA Approved Design Data
and referenced specifications.
1.2 Procurement Requirements
The McFarlane Receiving Code shall be “C”, except when ordering polyester thread which
will be receiving code “B”, and the purchase order shall be marked with this production
specification number. All purchase orders must include the additional information and
requirements as follows:
1.2.1 Cable
• All cable will be listed on the purchase order as to size, construction, and
composition and will be described as Cable meeting RR-W-410 Type VI,
class 2 (for 7x7) or class 3 (for 7x19)
• Material type to be specified as per RR-W-410 section 3.1.3.1 (302 or 304 SS
or carbon steel)
• Cable will also need to be specified as un-lubricated per RR-W-410
sections 3.6.3 and 6.2.1 in the purchase order lines. (Note: this is critical as
the default RR-W-410 comes lubricated, which is not compatible with
the silicone tubing.)
• Spool size shall be specified. Incorrect spool size is not always justification
for rejecting a shipment.
• All cable purchase orders shall specify that the manufacturer’s reel or spool
lot number must appear on each reel or spool and on every invoice and
Certification of Conformance.
• All cable purchase orders shall request that material be from a single
manufacturers’ production lot whenever feasible.
• Spools of cable shall be packaged such that the cable is protected from dirt
and abrasion during shipment. Cardboard or plastic wrap is acceptable
• Any special instructions for further processing during or after receiving
inspections shall be noted below a demarcation line on the PO form
separating McFarlane receiving instructions from vendor information. This
Page 4
05/17/2022
must also include the McFarlane Receiving Code “C” and this production
specification number and revision. An example of a special instruction would
be “Mark for resale and re-spool in 100 ft. lengths”.
1.2.2 Silicone Tubing
• All silicone rubber tubing must have the following properties when ordered:
o Hardness to be durometer of ± 5 (A scale)
o O.D. tolerance of ±0.050”
o I.D. tolerance of ±0.031”
o Tubing to be coated with corn starch based powder (outside only
preferred).
o Tubing to be certified to 14 CFR Part 23.853(a), Appendix F Part I (e)
and the FAA Materials Fire Test Handbook DOT/FAA/AR00/12
• Part Numbers in McFarlane’s ERP (Sage 100) system will be generated as
follows:

Page 5
05/17/2022
1.2.3 Leather Wrap Materials
1.2.4 Fire Testing

Preferred Vender
Aviation Consulting & Engineering
7718 53rd St N
Maize KS 67101
1.3 Certifications
Certificates of Conformance are required for all raw materials, hardware, and outside
processes such as heat treatment and plating. Certificates must meet the following
requirements:
• Material ordered to a McFarlane Drawing: Purchase order must reference the
drawing revision. A copy of the drawing must be included (1). Certificate of
Conformance must list the McFarlane Drawing and revision letter.
• Material ordered to a 3rd party specification: Certificate of Compliance must
reference the specification. If the McFarlane data requires a specific revision to a
specification, then (a) that revision must be listed on the purchase order, (b) a
note must be added to the purchase order drawing attention to the specification
revision, and (c) the certificate must list that revision level.
• For raw materials, certificate must include a mill test report, listing mechanical
properties and chemical composition limits.
• For material, the certificate must originate from the material manufacturer, not the
supplier.
• For hardware, the certificate must originate from the hardware item
manufacturer.
• Certificates must be dated and signed by an appropriate company official.
• A legible copy of an original certificate is acceptable.
(1) McFarlane policy, regarding external release of data, applies.

Page 6
05/17/2022
2. Applicable Data
All applicable top level data and drawings are listed in the “Master Item List” of the McFarlane
Data Control System (DCS). FAA Approved data is always given precedence to all other
specifications and reference material. In the event of conflict between the text of this
specification and the references cited herein, the text of this specification shall take
precedence except that all requirements of the McFarlane Aviation, Inc. FAA or Company
approved design data and FAA approved quality assurance procedures will take precedence.
3. Incoming Inspections
The following incoming inspections of the silicone coating and cable are required. An
inspection lot for cable and silicone consists of the same size, color, and/or construction that
was ordered on the same purchase order and are from the same supplier control group. The
results of these inspections shall be recorded in the Receiving Inspection Log, Form QC-201.
All inspections must be in compliance with Section 8.6 of the McFarlane Aviation Quality
Assurance Manual (QAM).
Note: Unless otherwise noted, the following applies to all inspections in Sections 3, 6,
& 9.
• Unless otherwise stated, inspections will be made using the Industry Standard ANSI/ASQ
Z1.4. Single Sampling Plans with the INSPECTION LEVEL and AQL as noted.
• An inspection lot shall be a group of articles fabricated on the same fixtures by the same
person using the same lot of raw materials and presented for inspection at the same time.
• Inspections will be recorded on McFarlane Aviation, Inc. Form QC-210. Inspection
equipment, fixtures and instruments will be in compliance with Chapter 7 of this production
specification before initiation of inspection procedures. Use standard measuring equipment
for inspection measurements unless otherwise stated.
• Defects for each inspection shall be classified as “Critical”, Major”, or “Minor”. These
designations serve two purposes:
o To make known to all personnel the potential consequences of the defect were it to
escape detection.
o To establish default dispositions for when a defect has been found.
• Definitions for Critical, Major, and Minor defects are found in the McFarlane Quality Manual.
• Default Dispositions:
o Critical and Major: Unless otherwise specified, an inspection rejection mandates that all
articles in the lot be screened for that particular defect. Articles rejected because of a
"Critical" or "Major" defect will be processed as per Section 8.7 of the McFarlane
Aviation, Inc. Quality Assurance Manual.
o Minor: Unless otherwise specified, it shall not be required to screen the lot for the found
defect, provided that the number of defects is less than or equal to the ‘Pass’ number for
the Inspection Level/AQL specified. Articles rejected because of a “Minor” defect will be
discarded or further processed as per Section 8.7 of the McFarlane Aviation, Inc. Quality
Assurance Manual.
• Unclassified inspections will be considered as producing minor defects unless any one
dimension is more than twice the allowable dimension.
• The phrase “use an Acceptance Number of 0 rejects” indicates:
▪ That if any defects are found, all parts must be inspected for that defect.
Page 7
05/17/2022
▪ The table arrows are disregarded when determining sample size.
• The phrase “Accept no rejects” is used in conjunction with a sampling plan not using an
ASQ/ANSI table. Example: ‘Inspect 5 units randomly taken from the lot. Accept no
rejects.’ If any defects are found, all parts must be inspected for that defect.
Additionally, the following specific inspections are required:
3.1.1 General
General incoming inspections as per Section 8.6 of the McFarlane Aviation, Inc. Quality
Assurance Manual are required for all incoming products. This inspection shall be
recorded as one entry on the inspection record. When any nonconformance is found, the
lot must be rejected or the total lot inspected for that defect.
Specification: General requirements
Defect Classification: Major
Method of Inspection: Visually inspect for all of the requirements of Section 8.6 of the
McFarlane Aviation, Inc. Quality Assurance Manual. Inspect for all purchase order
information and certifications required by Section 1 of this production specification.
Acceptance Criteria: All incoming materials shall conform to the applicable specifications
and purchase order requirements as outlined in Section 1 of this Production Specification
and the FAA Approved Design Data.
Instructions: Record as pass/fail on QC-210.
3.2.1 Cable Lubrication
Sampling Method: Inspections shall be made several feet from the beginning of each reel
of cable
Specifications: Internal lubrication.
Method of Inspection: Twist the cable open and hold a clean piece of white paper for
thirty seconds against the inner wire strands of the cable.
Acceptance Criteria: The white paper shall not show any oil stains.
Instructions: Any discrepancy requires rejection of the total reel of cable or inspections
every 50 feet for that discrepancy. Record as pass/fail on QC-210.
3.2.1.1 Cable Construction
Sampling Method: One sample per lot
Specifications: RR-W-410
Method of Inspection: Twist open a section of the cable and count the individual strands
and number of wires from one strand only. Visually compare the strand that had the wire
count to the remaining strands to verify equal number of wires in each strand.
Note: The cable is composed of a set number of strands which are, in turn, made up of a
number of wires. Example: A “7 x 19” cable consists of 7 twisted strands each comprised
of 19 wires.
Verify the lay of the wires and strands (left or right hand).
Note: The “lay” is the helical form taken by the wires in the strand AND by the strands in
the cable. A “right hand” lay means that, when viewed from above (perpendicular to the
cable axis), the individual wire (or strand) will angle away from the viewer on the right side
of the strand (or cable).
Page 8
05/17/2022
Acceptance Criteria: Cable must be in compliance with Section 3.16.1.4 and Table XL of
RR-W-410.
Instructions: Record as pass/fail on QC-210.
3.2.1.2 Length of Lay

Sampling Method: 1 sample per lot
Method of Inspection: Using calipers, measure the outer layer length of lay (rope lay
length).
Acceptance Criteria: Cable must be in compliance with Table XL of RR-W-410. The
following values are taken from the respective documents and are given here for reference:
Figure 1: Table XL from RR-W-410
Instructions: Record the length(s) of lay on QC-210.

Page 9
05/17/2022
3.2.1.3 Cable Composition
Sampling Method: One sample per lot/
Method of Inspection: Confirm cable composition using a magnet test. (Stainless steel
cable is only slightly attracted by a magnet whereas a magnet will easily attract carbon
steel cable). If the magnet test is not decisive, measure the electrical resistance over
several feet of cable. Use a digital ohm meter and standard testing probes for the test.
Galvanized or tin coated high carbon steel cable (Comp. “A”) will show less than .2 ohms
resistance/2 ft. where stainless steel cable (Comp. “B”) will show over one ohm of
resistance/2 ft. If again this test is indecisive, compare the electrical resistance reading of a
known section of cable the same size, composition and length with the cable being tested.
Acceptance Criteria: Cable composition must be match ordered material (Composition
“A” or “B”).
Instructions: Record as “Comp. A” or “Comp. B” on form QC-210.
3.2.1.4 Cable Dimension
Sampling Method: One Sample per lot
Method of Inspection: Using calibrated, precision micrometers, measure the diameter of
the cable.
Acceptance Criteria: Cable must be in compliance with Table I of the appropriate
specification.
Instructions: Record the diameter on form QC-210.
3.2.1.5 Cable Load Testing
Specifications: RR-W-410 & MIL-DTL-83420
Method of Inspection: One (1) sample for each new lot of cable purchased, select two (2)
appropriate sized MS20663 ball terminals or other appropriate sized MS standard hardware
and perform the appropriate distortion and breaking strength test as described in MIL-DTL-
83420 (Paragraph 3.5.6) for the RR-W-410 cable (Note see Table XL on RR-W-410 for
breaking strengths a copy of the data from Table XL is provided in Section 3.2.1.2 of this
production specification).
• Measure the length of the swaged cable assembly before and during the 60% proof
load test to determine the stretch per MIL-DTL-83420 (Paragraph 3.5.6).
• Perform a 100% load testing per MIL-DTL-83420 (Paragraph 3.5.3) as applicable to
check for cable assembly failure.
Acceptance Criteria: Samples must meet the requirements listed in the current approved
revision of Table XL on RR-W-410. Note: Test methods are to be performed as per
relevant sections for MIL-DTL-83420.
Instructions: Record the results as ‘pass’ or ‘fail” and list the categories as “Elongation
Proof Load Test” and “Breaking Strength Test” on form QC-210.

Page 10
05/17/2022
3.3.1 Silicone Rubber (color matching)
Sampling Method: One Sample per lot
Specifications: None
Method of Inspection: Visually verify that all incoming silicone material matches the
master color sample board located in the receiving area. Each spool/bag of tubing must be
checked against the master board color.
Acceptance Criteria: Tubing must visually match master color sample and must be
uniform in color with no splotches, stripes, fades, or other artifacts of discoloration.
Instructions: Record the results as “pass” or “fail” as a single line and list the category as
“Color Check” on form QC-210.
3.3.2 Silicone Rubber Hardness
Sampling Method: One sample per every 1000 feet from each distinct lot/size/color of
silicone tubing. Minimum of two samples.
Specifications: 7200 (use A scale) (micro hardness scale with conversion is allowed)
Method of Inspection: Using calibrated rubber hardness testing equipment, measure and
record the hardness of the silicon tubing.
Acceptance Criteria: Tubing must have a hardness range as specified on drawing 7200
Instructions: Record the results range as a single line and list the category as “Silicone
Hardness” on form QC-210.
3.3.3 Silicone Rubber Dimensions
Sampling Method: Check same samples selected for Inspection 3.3.2.
Specifications: Drawing 7200
Method of Inspection: Using calibrated equipment, measure and record the inner and
outer diameter of the silicon tubing.
Acceptance Criteria: Tubing must meet the requirements of Drawing 7200
Instructions: Record the result’s range as a single line per measurement and list the
categories as “ID” & “OD” on form QC-210.
3.3.4 Leather Hide (color matching)
Sampling Method: One sampler per hide
Method of Inspection: Verify dye lot of each hide received. Verify that there is no visual
damage to the material (cuts, blemishes, etc.). Cut one sample 3” x 14” from edge of the
hides from each dye lot.
Acceptance Criteria: Leather must not have visual imperfections, be uniform in color, and
approved by .

Page 11
05/17/2022
Instructions: Record dye lots and the results as “pass” or “fail” as a single line and list the
category as “Color Check” on form QC-210 attach documentation indicating
approval.
3.3.5 Thread Color
Sampling Method: One sample per
Method of Inspection: Visually verify that each incoming hide matches the master color
sample located in the receiving area.
Acceptance Criteria: Thread must visually match master color sample.
“Color Check” on form QC-210.
3.3.6 Thread Tensile (This inspection to be reconsidered after first lot is received)
Sampling Method: One sample per lot
Method of Inspection: using the tensile testing machine, pull thread sample to 15 lbs and
hold for 15 second
Acceptance Criteria: Thread must hold without breaking or unraveling.
“Tensile” on form QC-210.
3.3.7 Silicone Rubber Fire Resistance Test
Sampling Method: If no certifications are provided by vendor, 3 samplers from each lot to
be tested
NOTE: If no certification is listed, each part number must be tested a minimum of once
every three years to be checked when a new lot is received.
Specifications: 14 CFR Part 23.853 (a), Appendix F Part I (e) and FAA Materials Fire
Test Handbook, DOT/FAA/AR-00/12
Defect Classification: Critical
Method of Inspection: Check the files located at O:\Receiving\Silicone Burn Tests. Files
are to be saved as P/n_date-of-report.pdf
Date on test to be less than three years previous. If no test is present or the date is older
than listed, send samples to lab capable of doing the 2.5 IPM Horizontal Test per
associated specifications. Move old test report to “Obsolete” folder and save new test
report in this location using the above naming convention.
Acceptance Criteria: The averaged sample burn rate of the three samples to be less
than, 2.5 inches/minute
Instructions: Record the file name of the test report and list the category as burn rate on
form QC-210.
Page 12
05/17/2022
3.4 Hardware (Terminals, Clevis, Caps, Safety Wire, etc.)
Sampling Method: ANSI/ASQ Z1.4, Level S-2. Use an acceptance number of zero rejects.
Specifications: applicable standard, Customer Drawing, or McFarlane Drawing
Method of Inspection: Using calibrated equipment measure the dimensions listed on the
drawing or standard.
Acceptance Criteria: All dimensions must fall within the listed tolerance ranges.
Instructions: Record each dimension as its own line on form QC-210.
4. Storage Requirements
All cable in storage must be protected from dust and other shop contamination. Work areas
must be clean. The standard storage requirements of the McFarlane Aviation, Inc. Quality
Assurance Manual are applicable.
All tubing in storage must be protected from dust, oil, solvents, direct sunlight, and other shop
contamination. Work areas must be clean.
Leather and associated wrapping materials in storage must be protected from dust, oil,
solvents, direct sunlight, and other shop contamination. Work areas must be clean.
5A. Manufacturing Methods and Controls

Good housekeeping practices must be observed at all times in the cable assembly area.
Workbenches, tables, testing machines, or any surface that cables contact must be kept free
from dirt, cable trimmings, and any other foreign material produced during cable assembly or
by other nearby activities.
All materials rejected by production operator controls shall be promptly evaluated and
controlled per Section 8.7 of the McFarlane Aviation, Inc. Quality Assurance Manual. In the
case of a bad terminal swage or other terminal defect the terminal will be considered mutilated
when the terminal is cut off the cable with less than 1/2 inch of cable remaining with the
terminal. Cables and cable assemblies will be considered mutilated when a tight knot is tied in
the cable. When a cable assembly has been subjected to a pull test load
greater than 65% of the cable minimum breaking strength (see Table XL of
RR-W-410 or Section 3.2.1.2 of this production specification) the cable
must immediately be mutilated and scrapped.
Notes:
• The name or initials of the cable fabricator must be recorded on each job order.
• Do NOT use lubrication on swage dies other than hammer dies!
• Piece parts used in the assemblies applicable to this specification MUST be fully
accepted per their associated production specification.
o Prior to use, ensure an acceptance stamp is present on piece part package labeling
o The following Production Specifications are used in the production of door support
cable components.
PS1 ACA-10 Barrel Control Cable Fitting
Flight Control Cable Assemblies and Misc. Related
PS4
Subassemblies
Page 13
05/17/2022
For Production of the NAS287 Chain to Cable
Terminals, P/N 654 Special Stud Cable Terminals,
PS6
P/N 1770 05B-1 Chain Terminals, P/N 1783 No. 25
Chain Terminals and P/N 6146 Terminals
PS12 Part Number 655 Strap Fork Cable Terminal
PS18 Part Number 940
5A.1 Cutting Cable To Length: For high efficiency shank or ball type terminal cable
assemblies, the cable is cut to length and swaged in accordance with the requirements of
MIL-DTL-6117 or later revision. Allowance must be made for the growth in length of the
cable during the proof load testing.
5A.2 Marking the cable before swaging: One cable per cable-terminal assembly type,
will be marked (as a template) with paint or ink at a point where the cable just exits the
terminal with the cable fully inserted into the terminal. Visually align and mark all of the
remaining cables in a location corresponding to the template cable. All cables to be
swaged with the same terminal will be marked the same distance from the end of the
cable. Wipe the area to be marked with a clean rag to remove the oil film. Do not use any
type of solvent to clean the cable. Allow a few minutes for the paint or ink to dry before
installing the terminal. This mark is used to inspect that the cable remained fully engaged
in the terminal during the swaging process. The cable assembly shall be scrapped after
swaging if the mark is not at the beginning of the terminal bore or it is not detectable. The
marking is not required on ball terminals, or other terminals where inspection of the cable
engagement is possible after swaging.
5A.3 End Terminal Swaging: Terminals will be swaged as per the applicable
manufacture's operation instructions for the swaging machines. Only matched sets of
swaging dies must be used, and the die number shall be recorded in the remarks section
of the Job Order form. The job order number, die(s) used, and quantity of each die's use,
must also be recorded in the Rotary Swage Die Log spreadsheet located in O:\Mfg folder.
When a die has reached a swages remaining number of 0 on the Rotary Swage Die Log
spreadsheet, the die must be checked and/or serviced per McFarlane Procedure
Document PR18. The cable can be retained in position in the shank type terminals for
swaging by inserting the cable a little less than one half the terminal shank depth and
bending the cable before fully inserting the cable. After the completion of each swage, the
operator must check each terminal for proper after swage dimensions, workmanship, and
cable engagement in the terminal. If the finished cable assembly has two fork, eye, or
other directionally dependent terminals preform the following:
After the initial terminal has been swaged, hook terminal to alignment pin located at the
end of the calibrated tape measure and pull the cable straight. Rotationally clock the cable
using a permanent ink marker according to the top level drawing requirements (0, 45, 90°).
Careful note of the clocking mark while swaging the second end terminal must be
maintained.
5A.3.1 Pneumatic Hammer Type Swaging: Hammer type swaging machines (such
as our Model AT520D) shall only be used to swage terminals that are captured in the
dies. This type of machine must never be used to swage shank type terminals. The
inertial loads created by this type of equipment can cause undetectable fatigue cracking
in the shank type terminals.
Page 14
05/17/2022
The time required to swage the terminals to size must never exceed the maximum
number of seconds as listed by the manufacture. The dies must be repaired when the
terminals do not measure to proper after swage size after being swaged the allowed
number of seconds. Out of roundness of the swaged area by more than 20% (or 0.002”
for -2, -3, & -4 size spherical terminals) of the after swaged tolerance allowed is also an
indicator that the dies are in need of repair. Do not swage terminals with defective dies
as internal cracking from excessive work hardening of the metal can result.
Die Numbers, swage times, and pressures for various terminals is
given in Appendix IV. These values must be used!
5A.3.2 Rotating die rotary swage machines: This type of machine is used to swage
shank type terminals. The machine must be adjusted so that the dies come fully closed
and open the required amount. If the dies are allowed to open too far, the machine can
damage the cable and the terminal feed rate is hard to control. If the dies cannot open
far enough, the terminal will not feed into the machine. The terminal must never be
swaged more than one pass into the dies. If one pass does not bring the terminal
down to proper dimensions, the dies must be repaired. Taper in the O.D. of the shank
by more than 40% of the after swaged tolerance allowed and out of roundness of the
swaged area by more than 20% (or 0.001” for -2, -3, & -4 size terminals) of the after
swaged tolerances allowed are also indicators that the dies are in need of repair. Do
not swage terminals with defective dies as internal cracking from excessive work
hardening of the metal can result.
5A.3.3 Kearney type swage machines: This type of machine is used to swage shank
type terminals, for the purposes of this production specification, it is used on the second
end terminal after the silicone tubing has been
installed. Select the matched pair of roll dies (A
and B on figure to left) marked with the normal
size of the cable on which you wish to swage a
straight shank terminal. Install the roll dies on the
shaft of the machine so that the word "UPPER"
stamped on the flat side of the roll die on the
upper shaft (A on figure to left), and the word
"LOWER" stamped on the flat side of the roll die
on the lower shaft (B on figure to left) are visible
(facing out). This is necessary in order to be sure
that the grooves in the working faces of the two
roll dies are properly lined up with one another.
The single key in the shafts and keyways in the
roll dies will automatically position the two roll
dies in the proper index relationship to each
other. When the keys and keyways are lined up,
push the roll dies all the way onto the shafts and secure them with the special flat
washer and socket head bolts. Do not use tools to force the roll dies onto the shafts.
This should not be necessary.

Page 15
05/17/2022
As shown in the figure to the left, a Kearney type
swaging tool stretches and elongates the
terminal in the opposite direction as that of a
rotary or hammer type swage. Due to this effect,
caution must be taken to start the swage one
cable width from the bottom of the hole to
prevent the swage machine from pushing the
cable out during the swage operation.
Prepare the swage sample using the following
methods:
Figure I
Push the cable

into the fitting
until the end of
the cable reaches the bottom of the bore. Mark
the cable at point (A) as shown in Figure I.
Figure II
Place the cable beside the fitting shank and have mark (A)
placed flush with the bottom of the shank. Mark the shank at
point (B) using the end of the cable as shown in Figure II.
Figure III
Place the cable next to the mark (B) and mark the shank at point
(C) as shown in Figure III. (One cable diameter). Re-insert the
cable fully into the terminal, until mark A (Figure I) is flush with the
end of the terminal.
Advance the roll dies so that there is clearance to insert the cable and terminal between
the rollers and the end of the terminal not being swaged in against the end of the stop
(item C in equipment picture above). Adjust the stop till line C marked on the terminal is
in line with the center of the roller dies (dashed line D in equipment picture above). Do
not start the swage on line B, or the swaging process may push the cable out of the
terminal.
Rotate the roll dies until they have passed over the terminal shank. When the first pass
has been completed, a longitudinal fin or "flash" on two diametrically opposite sides of
the terminal will be noticeable on the swaged portion of the shank. To eliminate the
longitudinal fin, rotate the terminal 90 degrees from the first swaging position and pass it
through the rollers again. Rotate the sample 45° and repeat the swaging process,
rotate another 90° and repeat the swaging process a final time. Do not swage terminal
more than 4 passes as it can lead to work hardening and swage cracking.

Page 16
05/17/2022
Inspections per Section 6.3 must be performed prior to attaching silicone tubing
to cable assembly, Inspect swages once both ends of the cable have been
checked.
5A.4 Cable terminals shall be visually examined after swaging for any cracks or other
injurious defects. A magnifying glass shall be used as an aid to visually examine the
swaged area of every terminal.
5A.5 Silicone Injection
Controls which will include silicone injection, must have the cable wiped down with a rag
soaked in lacquer thinner to remove any oils left by the manufacturing process.
Silicon tubing which has powder on the interior surface, must have a rag soaked with
lacquer thinner run through the full length of the tube.
Controls are injected with silicone 1” behind terminal and then every 6” along cable length
per training video located in the following location:
O:\AeroCables\Training Photos and Videos\Cable Swage Silicone Inject and Trim
Video.mp4
Assure that the ends are properly clocked while the silicone dries.
5A.6 Trimming Silicone Tubing

Using a razor blade, trim tubing to angle on terminals per appropriate cable assembly
drawing. Ends must be smooth and uniform. Replace razor blade as needed to prevent
jagged/irregular cuts.
5A.7 Dusting Silicone Tubing
If tubing outside is too sticky to handle, a small amount of corn starch based powder may
be rubbed onto the outside of the tubing by a powdered rag or sponge.
5A.8 Leather Wrapping Cables
First assemble cable length and silicone coating and apply silicone adhesive inside the
silicone bonding the silicone to the steel cable.
Visually inspect area of hide to cut strips from for scars and blemishes. Mark as
needed.
Cut strips from hide avoiding scars and blemishes. Skive unfinished side down the long
edges of the leather strips using skiving machine.

Page 17
05/17/2022
Apply 3M 467MP ½” wide adhesive transfer tape (ATT) to the full length of the skived
edges.

Page 18
05/17/2022
Remove backer from ATT and fold first hem over using hem template.
Place in wide fixture so

edge of adhesive is at
edge of fixture
3M Adhesive
Fold on itself
creating seam edge

Page 19
05/17/2022
Remove backer from ATT and fold second hem over using smaller hem template.
Roll both hems flat using steel roller.

Setup sewing machine with size 25 needle and stitch length to .250”.
Fold leather strip in half flesh side together.

Page 20
05/17/2022
Hold hemmed edges flush to each other and stitch edges both at once, while guiding off
the presser foot. (NO THREAD) Needle holes should be .115-.175 from edged of strip.
Mark center of the length of the leather at the seam eedge with a white Staedtler
Omnichrom Pencil on the finished side of the leather.
Apply 3M 9472LE 1” wide ATT on the flesh side of the strip along the full length.

Page 21
05/17/2022
Perform inspection 6.5 at this time. Bond leather to silicone by removing ATT backer.
Align silicone so it is straight along the length of the leather.
5A.8.14 Start baseball stitch with one piece of thread that is at least 7’ long with a needle
threaded on each side.

Page 22
05/17/2022
Stitch Pattern:
Dashed lines indicate path is underneath the material.
Stitch down the length until you reach the center mark. Pull threads tight and tie off at the
center mark using a square knot tied off at least four times.
Apply a drop of Cyanoacrylate adhesive (Super Glue) to the knot.
Using a new length of thread, begin stitching the leather at the midpoint and continue down
the length of the silicon in the same manner as before. Finish at end and tie off and apply
adhesive to knot.
Assemble cable per McFarlane Drawing 7543 CENTER leather wrapped cable between
end terminals. Use End Cap 7542-XXX which fits snugly over the leather without

Page 23
05/17/2022
interfering with it. End Cap should slide easily into place and require no turning or forcing
to slide the end cap down over the leather and back up into place.
Fill voids in end caps with Silicone adhesive (Dowsil 732) until the silicon begins to
squeeze out of the end of the end cap. Wipe away excess silicone and allow to cure.
5B. Personnel Training

5B.1 Personnel qualified for the job of "control cable assembly" must satisfactorily demonstrate
the following skills and knowledge to the Manufacturing Section Manager. Personnel meeting
the qualification of this section will be qualified to assemble, swage, test and inspect control
assemblies.
5B.1.1 Qualified for the job of “control cable assembly” under McFarlane Aviation, Inc.
Production Specification 4.
5B.1.2 Ability to operate and control swages on a Kearny type swaging machine.
5B.1.3 Ability to operate and control silicone injection machine to properly adhere tubing to
cables.
5B.1.4 Ability to trim ends of silicone tubing to proper form, location, and appearance.
5B.2 Deleted
5B.3 Members of the McFarlane Engineering Staff that have experience and knowledge of the
requirements listed in 5B.1 and 5B.2 of McFarlane door cable assemblies may conduct any
inspection listed in this Production Specification.

Page 24
05/17/2022
5B.4 Personnel qualification will be recorded as per Section 6.2.2 of the McFarlane Aviation,
Inc. Quality Assurance Manual. Personnel qualified under 5B.1, or 5B.2 will receive recurrent
training within one year after completion of initial training or previous recurrent training.
Record of personnel qualified under Section 5B.3 will not be recorded. Personnel will be
evaluated periodically and given additional training as required.
5B.5 Personnel using the Skiving machine to be instructed on its use and show competence in
managing the machine, changing settings, and ensuring consistent product. No official training
matrix entry will be created for this training.
6. In-Process Inspections
Due to the low critical nature of these cables, the secondary personnel check/signoff of the in-
process inspections is waived.
6.1 60% proof load test
Sampling Method: 100% using an acceptance number of 0 defects.
Specification: 60% proof load test.
Method of Inspection: Pre-stretch and proof load each cable assembly to 60% of the
minimum breaking strength of the cable as per the Table XL in RR-W-410 or applicable top
level drawing.
Acceptance Criteria: Cable assembly must hold required applicable load without slipping
or failing.
Instructions: Record “pass” or “fail” as one line on form QC-210.
6.2 Cable assembly length and proper cable termination
Sampling Method: Inspection Level II with an acceptance number of 0 shall be used.
Specifications: Cable assembly length and proper cable termination
Method of Inspection: Methods of measuring the cable assembly lengths and the
tolerance for the cable assembly lengths shall be as specified in the McFarlane Aviation,
Inc. FAA approved design data. Visually inspect for proper cable termination and
construction (1x7, 7x7, 7x19, etc.). Construction may be determined by counting the
number of strands visible at the cut end if a visual inspection of the stranding does not yield
a definitive answer. Verify the proper type of cable has been used (Comp. A or Comp. B).
This can be accomplished visually (by experienced personnel), with a magnet, or with a
resistance test. Refer to Inspection 3.2.1.3 for details.
Acceptance Criteria: Cable assemblies shall have proper termination, cable type,
construction, and length as per FAA Approved Data.
Instructions:
• Record the range of measured lengths as one line with the category listed as
“LENGTH” on form QC-210.
• Record the cable termination as “PASS/FAIL” as one line with the category listed as
“TERMINALS” on form QC-210.
• Record the cable constructions as “PASS/FAIL” on one line with the category listed
as “CONST” on form QC-210.
• Record the cable composition as “PASS/FAIL” on one line with the category listed as
“COMP” on form QC-210.
Page 25
05/17/2022
6.3 Swage Quality and Dimensions
Specifications: Swage quality and dimensions
Method of Inspection: Inspect to determine conformance to the applicable drawing and
requirements not covered by the above test and inspections. Use a 5x minimum optical
magnifying glass when visually inspecting swaged terminals.
Acceptance Criteria:
• Shank Terminals - After swaged terminal dimensions "As" must extend a minimum
distance "X" from cable end of shank terminals as per applicable terminal standards
drawings.
Note: Terminals swaged with the Kearney swaging machine will not be exactly
round and must only pass the As dimensional check in a minimum of three places
while rotating around the shank.
• Ball Terminals - After swaged terminal dimensions "As" and "Bs" must meet the
specifications for ball terminals as per applicable terminal standards drawings. The
cable must extend through the fitting and protrude no more than .062” when the
fitting is positioned at the end of a cable assembly.
• All Fittings - Swaged areas of the terminals shall have a smooth surface free from
rapid dimensional changes in cross section, shall not become brittle as a result of
cold working, and shall not contain splits, cracks, and other injurious defects.
Note: Terminals swaged with the Kearney swaging machine will not be exactly
round and must only pass the As dimensional check in a minimum of three places
while rotating around the shank.
• Cable - The cable must show no defects and the cable assembly must be free from
dirt or other contamination.
Instructions: Record as “pass or fail” one line on form QC-210.
6.4 All Cable Assemblies (Swage Minimum Dimensions& Detail)
Sampling Method: One swaged assembly per lot and for each time the swage die is
changed, accept no defects.
Specification: Applicable terminal drawings and Section 5 of this specification.
Method of Inspection: Using a calibrated precision micrometer, measure and record the
range of each of the applicable swaged dimensions (taper), for each terminal used in the
cable assembly.
Acceptance Criteria: Swage dimensions must fall within the applicable terminal drawing
requirements.
Taper: Taper in the O.D. of the shank may not exceed 40% of the allowed after
swaged tolerance.
Instructions: Record each of the applicable dimensions as a range on a separate line on
form QC-210.

Page 26
05/17/2022
6.5 Cable Assembly Silicone Injection in Tubing – For Leather Wrapped Assy
Sampling Method: 100% with no defects allowed.
Specification: None
Method of Inspection: Visual inspection.
Acceptance Criteria: The tubing must have indication that silicone was injected thru the
skin by observation of needle marks on outside diameter of tubing throughout the length of
the silicone coating.
Instructions: Record as “pass” or “fail” one line on form QC-210.
6.6 Leather Wrap Assembly
Sampling Method: Each Leather Wrap Assembly
Specification: Cessna Door Cable Drawing
Method of Inspection: 6” Scale & Visual
Acceptance Criteria: Stitch spacing and pattern to match drawing requirements.
Stitching and leather should be pulled tight, with stitching being uniform and no gap
between leather edges visible.
Instructions: Record each of the applicable dimensions as pass/fail and visual inspection
as pass/fail on form QC-210.
6.7 100% Minimum Breaking Strength Load Test (When called out on drawing)
Sampling Method: 1 from the first ten cables produced, the 51st cable produced, the 101st
cable produced and so forth for every 50 cables in the lot. Samples to be identical except
for length. Samples to be at least 18” long. This is a destructive test and any assembly
tested is to be scrapped. If any changes were made to any equipment settings during the
swaging production, all cable assemblies produced after the change shall be considered a
new inspection lot.
Specification: RR-W-410 and applicable drawing
Method of Inspection: The door cable assembly being tested shall be subjected to a load
not less than the 100% minimum allowable breaking strength of the cable as specified by
RR-W-410 or other applicable cable standard or what is listed on the drawing, which ever
value is greater. Cable assemblies using the BM2487 series plan ball fittings shall be
tested to the 100% load forces listed in drawing BM2487, if value is largest between
drawing and terminal.
Prior to application of the load, the cable shall be marked at the point where it enters the
swaged end of the terminal. The load shall be applied slowly and in a straight line. The
test load shall be held for a minimum of five seconds.
Acceptance Criteria: Breaking of the cable before reaching the specified load, any
slippage of the cable in the terminal, or any signs of failure in the terminal or cable shall
constitute failure.
Instructions: Record maximum load held as one line on form QC-210

Page 27
05/17/2022
6.8 Swage length on 7516 (P/N PA46F53V001-001, -002, -003)
Sampling Method: First, 50th, every subsequent 50th assembly, and last assembly
Specification: 7516
Method of Inspection: Using calibrated equipment measure the length of the swaged
region.
Acceptance Criteria: Measurements must be within the tolerance range listed.
Instructions: Record the range of results as one line on form QC-210
7. Tool Calibration
When gages are used to measure finish swage dimensions and or other terminal dimensions,
the gages must be calibrated. All standard measuring equipment used to measure terminal
dimensions must be calibrated. Since the cable-testing machine must apply the specified test
load to the cable assembly, calibration of this machine is required.
7.1 When inspection gages are used, they must be calibrated when fabricated or repaired
and inspected for proper calibration at intervals as listed on the Equipment Calibration
Record, Form QC 510. Record the calibration inspection as per Section 7.1.5 of the
Quality Assurance Manual. The dimensions of any gage used shall be the limiting
dimension allowed by the terminal specification the gage is designed to measure. The
allowed gage tolerance from the specified dimension is .0005 inch. The tolerance is
unilateral from the limiting dimension allowed by the applicable approved specifications
such that any product dimension outside of the limiting specification dimensions would not
be accepted by the gage. In other words, the tolerance of the gage shall be such that a
slightly out of tolerance part or product would never be accepted by the gage.
7.2 The pull test machine uses air pressure controlled by a dead weight regulator. The
regulator system prevents excessive loads being applied to the cable assembly. This air
pressure acts upon an air cylinder piston with a low friction seal to apply the proper force to
the cable. An air pressure gage is used to monitor the process. A load cell is used to
measure the exact force being applied. The following calibrations of the cable test
machine components are required. Record the calibrations as per Section 7.1.5 of the
Quality Assurance Manual.
7.2.1 Regulator weights and shaft must be calibrated to the applicable weights listed on
Table I of this production specification titled, "Cable Test Machine Operating
Specifications".
Acceptable weight tolerance is plus or minus 3 grams. Calibration inspections of the
weights and shaft must be done every 5 years after the initial inspection or before
weights are placed in service after any repairs.
7.2.2 Since the air orifice size of the regulator is critical to the proper regulation of air
pressure, it must be inspected for the proper dimension, .252 inches (plus or minus
.001). This calibration check should be done every 36 months or after any repair. (The
orifice is hardened tool steel.)
7.2.3 The load cells and meters shall be calibrated for accuracy every other month, after
a cable failure during test, or after other situations that might have damaged the system.
The load cell must be calibrated at the points (in lbs.) that will be used to test cables. A
Page 28
05/17/2022
calibration correction chart must be maintained that reflects the corrected indications
required for each test point. The correction chart shall reflect an average of the meter
reading when the load is increasing to the test point and the meter reading when load is
decreasing to the test point. The test bench load cell shall be accurate without
correction to a maximum of 25% of the tolerance range allowed by the proof test. The
load cell system used to calibrate the test bench load cell must be accurate to 25% of
the test bench load cell accuracy requirements.
7.2.4 Test the MIL-PRF-16173 preservative compound periodically as detailed in
Procedure Specification MCSTD-3.
7.3 The swage dies, used in the rotary swaging machines must be created and maintained
per McFarlane Procedure Document PR18.
8. Identification and Packaging Requirements

The requirements of this section shall be met after the subassemblies have passed final
inspections through 9.1 as applicable. Final inspection 9.2 or 9.3 (as applicable) shall be
accomplished after the requirements of this section have been met. Cable assemblies
produced as one step for finished FAA-PMA product shall be completed and identified as per
McFarlane Production Specification Number 8. If any tag is attached directly to the cable it
must be removable.
8.1 For completed cable subassemblies that will be used at a later time as part of a FAA-
PMA product, place a tag that contains the following information on each cable, group of
cables, or its packaging.
The word "SUBASSEMBLY" followed by the identification number of the cable
subassembly as per the applicable McFarlane Aviation, Inc. FAA approved data.
The quantity when there is more than one in a package
The Job Order No.
Accepted Symbol:
8.2 Section 8 of this production specification is not applicable for completed cable
assemblies that are produced for immediate use as a FAA-PMA product. The
requirements of McFarlane Production Specification Number 8 shall apply to FAA-PMA
cable assemblies.
8.3 Place a tag(s) that contains the following information on each cable, group of cables, or
its packaging. If the tag is attached directly to the cable it must be removable.
McFarlane Logo
The P/N*
Quantity*
The Job Order Number*
Finished Symbol:
* denotes data that must also be bar coded.

Page 29
05/17/2022
8.4 Place a tag with the following signed certification statement on the package and the job
order:
This cable assembly(s) has been fabricated and tested in accordance with McFarlane Production Specification No. 118.
Inspection and test reports are on file with McFarlane Aviation, Inc. under Job Order ______________.
______________________________________________________ ______________________
Authorized Inspector Date
8.5 Place the cable assembly or assemblies in a plastic bag or other protective container.
An air tight seal is not required. The minimum cable coil diameter must be at least 60
times the diameter of the cable.
8.6 Replacement Parts:
None
9. Final Inspections
Note: Inspections must be accomplished by personnel qualified by Section 5B that did not
fabricate the assembly.
9.1 Silicone Tubing Cleanliness
Specification: None
Defect Classification: Minor
Acceptance Criteria: The tubing must have no grease, oil, or other dirt showing on the
outer surface. The surface of the silicone must be free of contamination, grit, splits or
lumps. If tubing is found to have defects, soiled areas may be cleaned with a mild
detergent and water on a clean rag. DO NOT USE SOLVENTS OR ALCOHOLS as it will
deteriorate the silicone surface.
9.1.1 Cable assembly silicone setback length and proper trimming
Specifications: Silicone coating proper setback length and trimming form
Method of Inspection: Using standard calibrated equipment, measure each door control
setback length (distance from terminal reference point to end of chamfer or corner of
silicone coating) and angle of taper (where applicable). Visually verify that taper cut is
uniform and clean and neat in appearance.
Acceptance Criteria: Silicone coating setback length and end taper shall meet the
requirements of the applicable top level drawing. Taper surface shall be smooth and
uniform and will not have any jagged edges or disruptions.
Instructions: Record the range of measured setback lengths as a single line and “pass” or
“fail” one line labeled “visual appearance on form QC-210.

Page 30
05/17/2022
9.1.2 Part number 41717238-15 and 41717238-16 Bolts
Sampling Method: ANSI/ASQ Z1.4, Level S2. Use an acceptance number of 0 rejects.
Specifications: Drawing 41717238-15 and 41717238-16
Method of Inspection: Using standard calibrated equipment, measure chamfer, hole,
and fillet that have been added to the bolt.
Acceptance Criteria: All dimensions must meet applicable drawing requirements.
Instructions: Record each measurement’s range of results as a single line on form
QC-210.
9.1.3 Cable Assembly Silicone Injection in Tubing
Specification: None
Acceptance Criteria: The tubing must have indication that silicone was injected thru the
coating by observation of needle marks on outside diameter of tubing throughout the length
of the coating.
9.2 Packaging and Identification: Cables
Sampling Method: Two (2) samples with no defects allowed.
Specification: Relevant assembly drawing, paragraph 8 of this specification.
Defect Classification: Minor
Acceptance Criteria: Inspected part must be complete. Identification, certification, and
packaging must be as required by Section 8 of this production specification. Application of
a label containing a finished or accepted symbol showing the job order number indicates
final acceptance of the part. Therefore, any defect found during this inspection must be
promptly corrected or the labeling, containing the symbol, removed.
9.3 Packaging and Identification: Terminals
Sampling Method: Two (2) samples with no defects allowed.
Specification: Relevant assembly drawing, paragraph 8 of this specification.
Acceptance Criteria: Inspected part must be complete. Identification, certification, and
packaging must be as required by Section 8 of this production specification. Application of
a label containing a finished or accepted symbol showing the job order number indicates
final acceptance of the part. Therefore, any defect found during this inspection must be

Page 31
05/17/2022
9.4 Dimensions: Bent and/or modified Terminals
Sampling Method: ANSI/ASQ Z1.4, Level S-4, Use an acceptance number of 0 rejects.
Specification: applicable drawing.
Method of Inspection: Using standard calibrated equipment, measure pertinent
dimensions.
Acceptance Criteria: All measured values must be within the tolerance ranges specified
on the approved data. Application of a label containing a finished or accepted symbol
showing the job order number indicates final acceptance of the part. Therefore, any defect
found during this inspection must be promptly corrected or the labeling, containing the
symbol, removed.
Instructions: List the range of measurements for each dimension as its own line on form
QC-210.
9.5 Cracking: Bent Terminals
Sampling Method: ANSI/ASQ Z1.4, Level S-4, Use an acceptance number of 0 rejects.
Specification: applicable drawing
Method of Inspection: using 10x magnification visually inspect inside and outside of bend
region.
Acceptance Criteria: Parts must be free of any signs of cracking. Application of a label
containing a finished or accepted symbol showing the job order number indicates final
acceptance of the part. Therefore, any defect found during this inspection must be
9.6 Silicone filled ends (P/N 7543)
Sampling Method: 100%
Specification: applicable drawing
Method of Inspection: After allowing silicone to cure, attempt to compress End Cap down
onto silicone tubing and visually inspect for silicon residue.
Acceptance Criteria: End cap should have no backlash, though compression of rubber is
acceptable, and silicone should not be present on the surface of the leather or cap. Fill
hole should be filled till a depressed level is visible or the silicone is level with the hole. The
silicone should not extend out of the fill hole or beyond any of the mating surfaces.
9.7 Manufactured Hardware (Terminals, Clevis, Caps, Safety Wire, etc.)
Sampling Method: ANSI/ASQ Z1.4, Level S-2. Use an Acceptance Number of Zero
Rejects.
Specifications: Applicable standard, Customer Drawing, or McFarlane Drawing
Method of Inspection: Using calibrated equipment measure the dimensions listed on the
drawing.
Acceptance Criteria: All dimensions must fall within the listed tolerance ranges.
Instructions: Record the range of results for each dimension as its own line on form
QC-210.
Page 32
05/17/2022
10. Return Handling Inspections

When parts are returned to McFarlane Aviation, the parts must be re-inspected by personnel
familiar with the production process. See the McFarlane Aviation Quality Assurance Manual;
Section 8.5.5, for general return handling procedures. The following specifics apply:
10.1 Requirements
McFarlane manufactured parts that have been returned must be received and inspected in
accordance with The McFarlane QC Manual Section 8.5.5.
10.1.1 Parts must have clear lot identification and complete traceability.
10.2 Inspections
10.2.1 Parts in Opened Packages that show signs of having been installed and
removed from an aircraft cannot be accepted. Kinks, contamination, damage
to the cable silicone coating, etc. disqualify the part from being accepted as
returned. Ask QC Manager for determination if in question.
Returned cables must have the length verified.
10.2.2 Un-opened packages must be inspected as follows:
• Visually inspect for scratches, or other damage to the part(s). No damage
is allowed.
• Verify that the packaging, labeling, and attachments are undamaged and
show NO signs of tampering/re-sealing.
10.3 Rework
10.3.1 Rework is limited to the following operations:
• Replacement of packaging, labeling, and or attachments.
• Soiled areas can be cleaned with a mild detergent and wiped with a clean rag.
10.4 Disposition
10.4.1 If parts meet the requirement of 10.1 and 10.2, after allowable rework of 10.3,
return parts to the Sales Department for re-stocking.
10.4.2 Unsatisfactory parts shall be dispositioned per section 8.5.5 of the McFarlane
Aviation Quality Assurance Manual.

Page 33
05/17/2022
Appendix I: Swaging Time, Pressure, and Dimensional Data for

Swaged Terminals Using AT520D Cable Swager
(Chart attached on next page)

Page 34
05/17/2022

Page 35
05/17/2022
Appendix II: Door Cable Silicon Application
• Cut cable approx. 6” longer than the overall length of finished part.
• Swage first terminal using standard rotary swager. (this end will be the terminal that has the most
exposed swaged portion of either of the terminals. As it will have a smoother looking swage).
• Check swaged dimensions listed in the PS and record on QC-210.
• Figure length of silicone tubing needed. (overall length of the assembly. minus setback on both
ends).
• Cut tubing to length using automatic tube cutter or the manual cutter (see photo).
• Chamfer ends if required by drawing or sample.

1. Choose correct size mandrel and install.

Page 36
05/17/2022
2. Check razor blade, change if needed.

3. Adjust blade to correct position in relation to the mandrel. Blade should be aligned with the
centerline of the mandrel.
4. Trim tube.
a. Slide tube onto mandrel to back edge of grove.
b. Turn on lathe.

Page 37
05/17/2022
c. Slowly introduce razor into tube.
d. Once it has made a complete rotation, pull razor back.
e. Pull tube off mandrel.

5. Trim end/s (both if required).
• Wipe down cable and terminal with lacquer thinner to remove excess oil before installing silicone
tube.
• Calculate stretch of cable and where it needs cut. Mark with red sharpie but don’t cut at this time.
When marking the cut line, also make a red sharpie mark perpendicular with cable for correct
terminal orientation if required.
• Slide the tubing onto the cable and silicone the tube on the terminal to the correct setback as
required by the sample or drawing.
• Once silicone has cured on the first terminal (typically 2 -3 hours). Put open end of cable in vise
and tighten to hold cable firmly. Pull back the silicone tube until you have about 4” past the red cut

Page 38
05/17/2022
line. Grip cable with special vice grips to hold tube back to swage second terminal. Make sure you
use the correct pliers and be careful not to damage/pinch the cable.
• Cut cable on red line, then swage second terminal.

• Check swage dimensions and record on QC-210, then clean off terminal to silicone the tube to the
correct set-back (see drawing or sample).
• Once dry, 2-3 hours, pull test the cable to appropriate value.
• Wrap tube with masking tape at injection spots (Approx. every 15” plus the vent hole/s).
• Set duration on injection pump. (An approx. time is 20 seconds of injection every 15” of cable. You
may need to adjust so you have a little silicone coming out of the vent hole when finished).
• Make pilot holes in the tube at the taped areas with stiff sharp wire to aide in the insertion of
injection/vent needles.

Page 39
05/17/2022
• Place the vent needle at far/opposite end of tube where starting to inject the silicone. This is
important as it allows the air to escape when injecting the silicone.
• Place injection needle into the tube at the opposite end of the vent, insert until you just feel it touch
the cable inside the tube. Injection gun to be at an angle pointing towards the end of the
assembly with the vent needles.
• Pull the trigger on the injection handle, wait until timer has expired. Proceed to next injection point
and repeat process along entire length of cable until reaching the vent hole.
• It is ideal when completing the last injection that the silicone will seep from the vent hole.

Page 40
05/17/2022
• When finished injecting it is important to stack on an elevated surface with the holes pointing down
to avoid silicone getting on the outside surface of the assembly.
• Once silicone has dried overnight, remove tape and clean off excess silicone from the outside of
the assembly.
• Do final inspections, clean the assembly and apply a light coat of corn starch. Place accepted
product in bag with appropriate label/s.


McFarlane Specification PS118 Rev L - Redacted

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

McFarlane Specification PS118 Rev L - Redacted

Uploaded by

Copyright:

Available Formats

Page 1

McFarlane Aviation, Inc.

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

1. Material Specifications and Procurement Requirements

CONFIDENTIAL AND PROPRIETARY

1.2.4 Fire Testing

CONFIDENTIAL AND PROPRIETARY

3.2.1.2 Length of Lay

Instructions: Record the length(s) of lay on QC-210.

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

5A. Manufacturing Methods and Controls

CONFIDENTIAL AND PROPRIETARY

Push the cable

CONFIDENTIAL AND PROPRIETARY

5A.6 Trimming Silicone Tubing

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

Place in wide fixture so

CONFIDENTIAL AND PROPRIETARY

Roll both hems flat using steel roller.

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

5B. Personnel Training

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

8. Identification and Packaging Requirements

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

10. Return Handling Inspections

CONFIDENTIAL AND PROPRIETARY

Appendix I: Swaging Time, Pressure, and Dimensional Data for

(Chart attached on next page)

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

• Chamfer ends if required by drawing or sample.

CONFIDENTIAL AND PROPRIETARY

2. Check razor blade, change if needed.

CONFIDENTIAL AND PROPRIETARY

d. Once it has made a complete rotation, pull razor back.

e. Pull tube off mandrel.

CONFIDENTIAL AND PROPRIETARY

• Cut cable on red line, then swage second terminal.

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

CONFIDENTIAL AND PROPRIETARY

You might also like