Introduction
Before every swage, there's one critical step that determines whether your fitting will hold pressure — tool inspection. At Top Flight Tools, we’ve helped thousands of technicians, engineers, and repair shops avoid costly do-overs and safety failures by understanding and applying the pre-inspection process outlined in the 3KSI Permaswage® system.
In this post, we’ll walk you through the essential inspection steps for DLT tooling, show you what to look for, and share a few pro tips to get it right every time.
Why Pre-Inspection Is Critical
A faulty swage can lead to:
Leaks in flight-critical hydraulic lines
Tube damage from tool misalignment
Costly rework or even equipment grounding
Fortunately, DLT tooling is designed to be durable — if maintained properly.
âś… 12-Step Tool Inspection Checklist
Here’s a breakdown of what you should verify before swaging:
- Head Assembly is free from cracks or damage
- Yoke, Die Blocks & End Plates show no wear or bending
- Die Set matches your tube size (marked on each die)
- Dies seat properly with no movement when loaded
- Tool cavity is clean and lubricated (see lube areas in image below)
- Screw bolts are tight and unstripped
- Pump connection is secure and free of hydraulic leaks
- Max pressure is set correctly: 10,000 ± 250 PSI
- Dies are not chipped or have any burrs
- Die number matches the size listed in the tooling chart
- Fitting is inserted to proper depth (using go/no-go gauge)
- Safety labels are in place and legible
đź’ˇ Pro Tip: Use a small flashlight and brush to clean out die grooves before each job.
Don’t Forget to Check the Dies
Damaged dies can ruin even the best prep work. Check for:
Cracked or over-compressed slots
Excessive wear from repeated swaging
Here's an example image we use to educate customers on what damage looks like:
Final Thoughts Whether you're swaging in the hangar, on the line, or in the field, your results are only as good as your tool prep. At Top Flight Tools, we inspect every head, die, and kit we sell — and we give you the SOP reference tools so you can do the same.
đź›’ Need replacement dies or DLT kits? Check out our inventory or contact us for expert recommendations.
⚠️ Disclaimer Top Flight Tools (TFT) is an independent reseller and is not affiliated with, sponsored by, or endorsed by Permaswage® or Precision Castparts Corp. (PCC). All product names, trademarks, and registered trademarks are the property of their respective owners. Any reference to Permaswage® products, specifications, or part numbers is provided for informational purposes only. All Permaswage® trademarks and part numbers remain the property of their respective companies.
While every effort is made to ensure the accuracy of the information provided, it is the customer’s responsibility to verify all specifications, compatibility, and suitability of products for their intended application prior to use. TFT assumes no liability for errors, omissions, or the misuse or misapplication of this information, and disclaims any responsibility for damages resulting from reliance on it.