Dyform/Norseman Advice Needed

[v40163]

This is my first post so please bear with me if I do something wrong... )

I'm in the process of installing my first 3/8" Norseman fitting onto 10mm Dyform wire using new cones. With the cone inserted up the wire by an amount equal to 1 1/2 x wire diameter, I could only screw the eye into the fitting about 7 (out of a possible 12) threads. Upon inspecting my old 1x19 conventional wire/cone that came out of the fitting I can see that the end of the cone is much closer than 1 1/2 x WD to the end of the strands, and the bitter ends of the outer strands exactly match the taper of the cone on their way toward the core strands.

I gently sanded the end of the new wire (with installed cone) on a belt sander and noticed that as I sanded some length off of the wire, the strands gradually came to not touch the core strands. Then when I re-installed the eye in the fitting, the strands closed up again and I was able to screw the eye in further.

I continued this until the cone was about 1 x WD from the end of the strands. I can now screw the eye in about 9 1/2 turns. Upon disassembling the fitting, I can see that the outer strands do not appear to exactly follow the taper of the end of the cone, because they hit the inner core first.

It seems reasonable that if I continue to sand the wire down, thus bringing the ends of the wire strands closer to the end of the cone, that at some point the bitter ends of the strands will exactly match the taper of the end of the cone with only a tiny gap between the ends of the outer strands and the inner core of the wire.

Naturally, I was doing this at 11 o'clock last night, so Navtec wasn't open to ask them...

Am I thinking wrong, or what?


Thanks in advance,
Ray Russell
'77 Valiant 40