How to Make a Wire Eye

When replacing the shrouds, or adding a topping lift to a sailboat, it may be necessary to fashion an eye at the end of a length of wire rope. Combined with a thimble, the eye reduces friction between a deck-mounted chain plate or turnbuckle. The components you will need can be acquired at many home improvement centers or marine supply houses. Provided you have the proper tools, and someone to lend a pair of helping hands, making a wire eye only takes a few minutes.

Things You'll Need

  • Length of marine-grade wire rope (ex: 7x7 lanyard wire)
  • Thimble
  • 2 copper swaging ovals
  • Cable cutter
  • Swaging tool
  • Riggers tape (optional)
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Instructions

    • 1

      Make a fresh, flush cut on the end of the wire rope. This will remove any burrs.

    • 2

      Slip both swaging ovals onto the wire rope. Push them up several inches, but do not crimp them.

    • 3

      Bend the end of wire rope around the thimble. Allow two to three inches of wire rope to extend past the end of the thimble. Lay the extra wire alongside the rest of the wire rope.

    • 4

      Slide the swaging ovals over the end of the wire rope. Slide one down until it is directly above the portion of the wire rope which has been wrapped around the thimble. Have your helper hold the thimble and wire rope in place while you perform this task. A copper swaging oval has a center slot with circular ends. Once you slide it over the bent-over portion of the wire rope, it secures both the standing portion and the end you've wrapped around the thimble.

    • 5

      Open the jaws of the swaging tool, and slip them over the copper swaging oval located directly above the point where the wire rope is wrapped around the thimble. Close the jaws of the swaging tool, taking extreme care not to accidentally injure your helper.

    • 6

      Press the handles of the swaging tool together. This will crush the soft copper swaging oval and secure the wire rope. Repeat this action several times, moving the jaws of the swaging tool up the surface of the swaging oval.

    • 7

      Slide the second swaging oval upward about two inches, and repeat the same crimping action you performed on the first swaging oval, crushing it down in several places along its length. You have fashioned a strong wire eye capable of withstanding great stress.

    • 8

      Wrap a bit of riggers tape around the end of the wire rope, but leave the wire eye uncovered. This will help prevent any nicks or cuts should you brush against the wire rope.