Swage Terminals: wire size and hire of tool?

Go and talk to your local riggers. A proper swaging machine is a large, heavy hydraulic contraption. Not usually available from tool hire places. Also they do require a fair amount of skill to use to avoid "banana" swages.
 
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I want to buy some swage terminals and forks for my Guard Rails. They measure 7mm diameter outside the plastic, what would be the diameter of the wire core?

[/ QUOTE ] At a guess between 4 and 6mm - not the answer you wanted.... The only way to be sure is measure the core - I have seen different coated wire (same OD) with considerably different thicknesses of coating.
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Probably 4mm.
Plastic coated wire is not currently in fashion, believe its not allowed for offshore racing now? You tend to get corrosion and broken strands hidden by the plastic.
I would get proper roll swages done by a rigger I trusted, particularly if you want swaged on studs to go through stanchions. Although I have seen good talurits put on with DIY kit, and bad 'professional' roll splices, I would want lifelines done by someone experienced. Unlike shrouds or halyards, they don't take any real load until a crisis situation.
 
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