Both Intermediate and Terminal pins begin as a piece of 302 stainless steel rod about .187 " diameter. They are cut to length, then the blade portion of this rod is rotary swaged to a diameter of .094. The pins destined to become terminal pins, are then trimmed and finished and drilled to a depth of .75". The pins which are to become intermediate pins, are offset stamped. The shank end is then drilled to an ID of .101" through the newly formed offset. These pins are then trimmed and finished.
The process for mounting each of these pins to the cable is similar.
Each is threaded onto the cable then swaged or crimped to the cable. The
terminal pin is then ready for inspection. The intermediate pin can have
excess cable protruding from the hole in the end of the pin used in the
terminal position, which must be ground off. This excess cable is ground
off until it is smooth and even with the edge of the pin. This smooth
edge is then observed for alignment between the OD of the cable and the
ID of the pin. There is no visible demarcation of these surfaces, they
appear as continuous. All pins/cable assemblies are then subjected to
a 300 pound for 3 second test for joint integrity.