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Cable lacing
Cable lacing
Cable lacing
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Laced wiring harness from a Tesla coil

Cable lacing is a method for tying wiring harnesses and cable looms, traditionally used in telecommunication, naval, and aerospace applications. This old cable management technique, taught to generations of lineworkers,[1] is still used in some modern applications since it does not create obstructions along the length of the cable, avoiding the handling problems of cables groomed by plastic or hook-and-loop cable ties.

Cable lacing uses a thin cord, which is traditionally made of waxed linen, to bind together a group of cables using a series of running lockstitches. Flat lacing tapes made of modern materials such as nylon, polyester, Teflon, fiberglass, and Nomex are also available with a variety of coatings to improve knot holding.[2]

PABX with extensive cable lacing

Styles

[edit]

The lacing begins and ends with a whipping or other knot to secure the free ends. Wraps are spaced relative to the overall harness diameter to maintain the wiring in a tight, neat bundle, and the ends are then neatly trimmed. In addition to continuous or running lacing, there are a variety of lacing patterns used in different circumstances. In some cases stand-alone knots called spot ties are also used.[3] For lashing large cables and cable bundles to support structures in telecommunications applications, there are three named cable lacing styles: the box stitch,[4] the Chicago stitch, and the Kansas City stitch.[5]

The Kansas City and Chicago stitches are adapted to multiple cables; each forms the cables into a rectangular structure by wrapping wax string around each pair within the bundle. They both require a cable sewing needle to tie, such as the Jonard 2257 or 3209, or an Evans needle like Jonard 287.[6] The needle is used by pushing its blade through the bundle, inserting the wax string through its loop, and drawing it with the wax string back through the bundle.

The Chicago stitch can be used to bind cables in free space, or to bind them to a support; in the latter case, the stitch is started by tying around the support, and then the Chicago stitch is performed as though in free space. The Kansas City stitch lays the bundle flat against the support, and each internal wrapping in the bundle also wraps the support.[7]

The box stitch is suited to one or few cables, and is suited to binding a large cable or a small number of cables to a support. It will make a cylindrical structure rather than a rectangle, but it is less time-consuming, and it does not require a tool.

Some organizations have in-house standards to which cable lacing must conform, for example NASA specifies its cable lacing techniques in chapter 9 of NASA-STD-8739.4.[8]

Examples

[edit]
  • Traditional waxed cord lacing made with a series of running lockstitches based on the figure-eight knot
    Traditional waxed cord lacing made with a series of running lockstitches based on the figure-eight knot
  • A variety of lacing techniques are visible on the cabling of the NASA Mars Exploration Rover Spirit and its lander.
    A variety of lacing techniques are visible on the cabling of the NASA Mars Exploration Rover Spirit and its lander.
  • This style of continuous lacing, also called "marline hitching", is based on a series of overhand knots. A series of half-hitches, while visually similar, is not recommended for this application.[9]
    This style of continuous lacing, also called "marline hitching", is based on a series of overhand knots. A series of half-hitches, while visually similar, is not recommended for this application.[9]
  • Spot ties formed with a clove hitch topped by a reef knot made in modern Nomex lacing tape. A surgeon's knot is an acceptable substitute for the reef knot.[10]
    Spot ties formed with a clove hitch topped by a reef knot made in modern Nomex lacing tape. A surgeon's knot is an acceptable substitute for the reef knot.[10]
  • A box stitch used to secure a bundle of wires to a frame. The wires are bundled with a running stitch, and are secured to the frame with the box stitch.
    A box stitch used to secure a bundle of wires to a frame. The wires are bundled with a running stitch, and are secured to the frame with the box stitch.
  • View of the box stitch showing how the cables are secured to the support.
    View of the box stitch showing how the cables are secured to the support.
  • Cables laced together in a bundle using a Chicago stitch. In this case, the cables are not secured to a structure, but the cable lacing is used to keep them in a rectangular form in the riser.
    Cables laced together in a bundle using a Chicago stitch. In this case, the cables are not secured to a structure, but the cable lacing is used to keep them in a rectangular form in the riser.
  • A Chicago stitch where some additional cables (grey plastic, left) have been added to an existing bundle (fabric cables, right).
    A Chicago stitch where some additional cables (grey plastic, left) have been added to an existing bundle (fabric cables, right).
  • Cables laced together using a Kansas City stitch.
    Cables laced together using a Kansas City stitch.
  • Side view of cables laced together and secured to a frame with a Kansas City stitch.
    Side view of cables laced together and secured to a frame with a Kansas City stitch.
  • Back view of a bundle of cables secured to a frame with a Kansas City stitch. The bundle is stitched to the support in multiple places.
    Back view of a bundle of cables secured to a frame with a Kansas City stitch. The bundle is stitched to the support in multiple places.
  • Jonard 2257 needle used to tie the Kansas City and Chicago stitches.
    Jonard 2257 needle used to tie the Kansas City and Chicago stitches.

Notes and references

[edit]
[edit]
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Cable lacing

View on Grokipedia
from Grokipedia
Cable lacing is a traditional technique used to bundle and secure wiring harnesses and cable looms by tying them with flat lacing tape, typically employing running lockstitches and knots such as clove hitches or square knots to ensure organized, stress-free assemblies without damaging the wires. This method has been employed for decades in demanding environments, including , , , naval vessels, and broadcast facilities, where it provides reliable, long-lasting cable organization that withstands vibration, temperature extremes, and environmental stresses. Developed as an early alternative to modern fasteners like cable ties, cable lacing originated in industries requiring precise and durable wiring solutions, such as linemen's practices and applications, with standardized procedures documented as early as the mid-20th century. In aerospace contexts, organizations like have codified its use in standards such as NASA-STD-8739.4, which specifies techniques including spot ties, flat stitching for breakouts, and precise spacing based on bundle to prevent slippage or wire stress. The process begins with a starting , followed by evenly spaced stitches—typically 12.7 mm to 76.2 mm apart depending on harness size—and ends with a closing stitch and trimmed tails to avoid sharp edges or contaminants. Materials for lacing tape vary by application but commonly include waxed , , , or high-temperature options like to match environmental demands, ensuring the bundles remain flexible and secure across a wide range of wire gauges from fine 22 AWG to heavy power cables. Compared to plastic cable ties, which can degrade, become brittle, or leave snagging edges, lacing offers superior longevity, prevents insulation damage like cold flow, and allows for easy inspection and rework, making it preferable in critical systems such as harnesses or medical equipment. Despite the prevalence of zip ties in general use, cable lacing persists in specialized fields for its unobtrusive profile and compliance with stringent safety standards.

Definition and History

Definition and Purpose

Cable lacing is a traditional method for bundling and securing wiring harnesses or cable looms, employing a continuous cord to form neat, secure assemblies that avoid sharp edges and unnecessary bulk. This technique involves passing the cord through the bundle in a series of stitches to hold cables parallel and organized, facilitating efficient routing in confined areas. The primary purpose of cable lacing is to organize cables within tight spaces, minimize movement that could lead to wear, and prevent chafing between wires or against surrounding structures, thereby enhancing system reliability in demanding environments such as those with high . By maintaining straight, parallel conductors without excessive tension, it reduces the risk of insulation damage and ensures long-term stability, outperforming alternatives that might obstruct access or introduce failure points. In comparison to modern alternatives like zip ties or straps, cable lacing provides superior durability, as it resists and does not leave brittle remnants or sharp protrusions that could snag or injure during handling. This results in a more aesthetic, professional finish suitable for precision applications, while creating a flexible yet firm bundle that permits easy inspection and maintenance without disassembly. Its historical use traces back to early 20th-century for managing complex wire runs.

Historical Development

The earliest documented use of cable lacing techniques dates to 1905, when they were described in linework for securing overhead wires. In the May issue of , the article "Cable Sewing Knots" detailed specific knots, such as the double strap hitch and , taught to linemen for binding and repairing cable bundles in installations, emphasizing their utility in maintaining secure, weather-resistant connections. This method addressed the growing demands of expanding rural and urban networks, where loose or damaged wires posed significant risks to service reliability. By the early , cable lacing evolved through adoption in naval and sectors, where it supported the bundling of electrical systems in ships and early , drawing from practices refined by the —as evidenced in 1907 articles in Telephony magazine detailing "Manson's Practical Suggestions" for cable sewing in line construction. Bell System influences promoted uniform knot patterns suitable for reliable applications. Post-World War II, cable lacing saw formal standardization in the aerospace industry, building on wartime innovations and telecommunications precedents from the . The (FAA) and military specifications, such as MIL-T-43435 for lacing tape materials, codified techniques for aircraft harnesses to meet safety and durability requirements. NASA's NASA-STD-8739.4, first issued in the late and revised through subsequent decades, explicitly outlines lacing procedures for flight hardware, including starting stitches and tie spacing, to ensure compliance in mission-critical systems. These standards emphasized lacing's advantages over emerging alternatives like plastic ties, prioritizing abrasion resistance and ease of inspection. Despite the rise of synthetic fasteners since the mid-20th century, cable lacing persists in safety-critical industries through 2025, driven by regulatory mandates that favor its proven performance in high-vibration and environments. Aerospace and naval standards, including ongoing adherence to -STD-8739.4 and MIL-SPEC equivalents, require lacing for applications where alternatives may fail under thermal cycling or mechanical stress, maintaining its role in preventing cable damage and ensuring system longevity.

Materials and Tools

Lacing Materials

Cable lacing traditionally employs waxed cord, valued for its excellent grip due to the wax coating, inherent flexibility that allows tight bundling without cracking, and resistance to fraying during repeated handling or tension. This material, often specified under MIL-T-713 Type N, consists of pure fibers impregnated with to enhance durability and prevent slippage in knots. Modern alternatives to linen include flat or braided tapes made from , , Teflon (PTFE), , and , which offer improved performance in demanding environments. These materials are typically coated with , , or rubber finishes to provide for easier manipulation, reduced during installation, and enhanced longevity against abrasion. For instance, and tapes are common for general electrical bundling, while Teflon provides superior protection. Key properties of lacing materials include tensile strength ranging from 20 to 50 pounds for common twines like size 8 waxed (48 pounds breaking strength) or equivalent synthetics, ensuring secure holds without snapping under load. Diameters are typically 0.5 to 1 mm (e.g., 1.02 mm for waxed cord), allowing precise stitching around bundles. Environmental resistance varies, with tapes enduring temperatures up to 260°C (500°F) continuously, alongside non-flammability and fluid repellency for use. Material selection depends on the application: waxed is preferred for historical authenticity in restoration projects or low-stress electronics, while synthetics like or Teflon are chosen for high-temperature (e.g., compartments) or chemical exposure scenarios, such as in wiring harnesses where resistance to oils and solvents is critical. or suits general industrial bundling due to their balance of strength and cost-effectiveness.

Required Tools

Cable lacing requires a set of specialized tools to ensure precise and efficient bundling of cables, with the primary instrument being the lacing needle. These needles, such as the Jonard JIC-287 model, feature a curved notched design suitable for diameters up to 1 mm, and typically measure 5 to 6 inches in length for maneuverability in tight spaces. Evans lacing needles, another common variant, offer similar designs tailored for waxed compatibility, allowing for smooth threading without snagging. Lacing needles are constructed from durable materials like for strength or for resistance in humid environments, and they come in straight or curved configurations to improve access within dense cable bundles. Auxiliary tools complement the needle by aiding in loop formation and finishing; a fid or , often made of with a tapered point, is used to pry open and tighten stitches for uniform tension. or side cutters, with sharp, fine blades, are essential for cleanly trimming ends to prevent fraying, while a pot—typically a small electric or manual device maintaining wax at 150-180°F—enables on-site waxing of twine for enhanced grip. In high-volume production settings, optional modern aids like automated twine dispensers streamline the process by feeding precise lengths of , reducing manual handling and waste, though they are not required for traditional hand-lacing. These tools collectively support compatibility with various twine types, such as or , as detailed in lacing materials.

Lacing Techniques

Basic Principles

Cable lacing begins with thorough preparation of the cable bundle to ensure and effectiveness. Individual cables are aligned parallel to one another and straightened using a wire , which promotes uniform bundling and reduces the risk of abrasion during handling or operation. This step also involves verifying that the cables are clean and free from sharp edges or damage that could compromise the lacing process or insulation integrity. The foundational technique involves spacing the lacing wraps at intervals roughly equal to the bundle's diameter—for instance, every 1 to 2 inches for a 1-inch bundle—to provide consistent support along the length without introducing undue stiffness. Lacing starts and ends with secure knots, such as a square knot, , or half-hitch, positioned to prevent slippage while distributing load evenly. The is then passed around the bundle, looped through the previous wrap or directly around the cables, and pulled taut to form each stitch. Throughout, even tension is applied to hold the bundle firmly without crushing the wire insulation or deforming the cables.

Specific Styles

Cable lacing employs several distinct styles tailored to bundle configurations and installation requirements, each utilizing variations of lockstitches to secure wires or cables effectively. The box stitch involves a series of over-under lockstitches that wrap cylindrically around small bundles of one to two cables, creating a tight, uniform enclosure without the need for additional tools beyond the lacing cord. This pattern is particularly suited for round, compact bundles where minimal material and simple execution are prioritized, ensuring even pressure distribution along the length. In contrast, the Chicago stitch features a rectangular interlacing configuration that binds multiple cables together or to support structures, employing double strands of cord passed between cables and tightened sequentially with square knots. It consumes more to achieve enhanced security, making it ideal for grouped cables requiring robust attachment to slats or vertical supports in setups. The Kansas City stitch, designed to flatten bundles against a mounting surface, alternates stitch directions by passing the cord under the support slat, looping over the on top of the cable, and tightening from below for a secure hold. This method incorporates direct wrapping around both the bundle and support, rendering it appropriate for single-layer installations on wall-mounted racks or looms where planarity and stability are essential. Beyond these named patterns, cable lacing distinguishes between continuous running lacing, which threads lockstitches evenly along the full length of the bundle for uniform support and even load distribution, and spot ties, which apply periodic knots at intervals for faster application in less demanding scenarios. Continuous running is preferred for harnesses in confined spaces like panels, adhering to basic spacing rules of no more than 12.7 mm between stitches for small diameters, while spot ties suit quick securing where supports exceed 30 cm apart.

Applications and Examples

Industrial Applications

Cable lacing is widely employed in the and sectors for securing wiring harnesses in , where it provides essential vibration resistance and contributes to weight savings critical for performance and . In these applications, lacing tape materials such as , , or TFE-fluorocarbon are specified to meet standards like A-A-52080 through A-A-52084, ensuring long-term integrity under extreme conditions including high temperatures up to 800°F and fluid exposure. NASA-STD-8739.4 mandates precise lacing techniques for interconnecting cables and harnesses, including spot ties with clove hitches spaced according to bundle diameter (e.g., 12.7 mm for harnesses ≤6.4 mm) to prevent slippage without damaging insulation. Similarly, FAA AC 21-99 outlines lacing procedures for aircraft wire bundles, emphasizing tight but non-constricting ties to maintain bundle shape during vibration. In , cable lacing is effectively mandatory, as the U.S. has prohibited plastic cable ties on aerospace wire harnesses due to chafing risks, approving alternatives like lacing fasteners that comply with MIL-T-43435 for binding looms in jets. In naval and maritime environments, cable lacing secures shipboard wiring against the challenges of saltwater and constant motion from waves and vibrations, using waxed lacing cord (e.g., #6 or #8 sizes) to bundle conductors laid straight and parallel without twisting. The U.S. Navy's Electronic Installation Practices Manual (NAVSHIPS 900171) details lock and running stitches at 1/2-inch intervals to organize cables, support them during repairs, and resist unraveling under dynamic loads, with non-corrosive shuttles like aluminum or fiber recommended to avoid in humid, saline conditions. NAVSEA Standard Item 009-73 governs shipboard procedures for installation and to ensure reliability in corrosive maritime settings. Telecommunications infrastructure relies on cable lacing for historical and ongoing applications in private automatic branch exchange (PABX) systems and fiber optic bundles, enabling clean, organized routing within equipment racks and switchboards to facilitate and maintenance access. Telephone Operations Practice 256-050-204 specifies lacing methods like the "" stitch for vertical rack break-offs, bundling large cables (≥5/8 inch) singly or small ones (≤5/8 inch) in groups of 2-3 with square knots every 12 inches, while fiber optics are routed separately with minimum bend radii of 10-20 times cable diameter to prevent damage. These techniques support high-density installations in central office environments, using fire-retardant materials to manage bundles without crossover or tension. In other industrial sectors, cable lacing is applied in electrical panels for manufacturing equipment and automotive wiring looms, adhering to standards current as of 2025 for durable, non-abrasive bundling. For control panels, waxed cord laces wiring in legacy and select modern setups to organize circuits and reduce clutter, providing secure without insulation damage. In automotive contexts, it secures harnesses in high-reliability applications like performance vehicles, using MIL-T-43435-compliant tapes for , vibration-resistant looms, particularly in custom or setups.

Practical Examples

In wiring harnesses, cable lacing with a box stitch is employed to secure bundles while maintaining precise spacing for high-voltage insulation, as seen in flight hardware assemblies where lock stitches are applied at regular intervals to prevent wire crossover and ensure uniform tension. This technique, detailed in standards, involves starting with a spot tie and progressing with running lockstitches spaced according to bundle , typically 25-50 mm apart for diameters under 12.7 mm, to support breakouts without stressing terminations. In 20th-century telephone exchange setups, such as private automatic branch exchange (PABX) harnesses, the Chicago stitch is used to mount cable forms to relay rack supports, creating secure, aligned bundles for connections to terminal strips and relays. This style fastens cables perpendicular to brackets with a series of wrapping turns and lock knots, as specified in AT&T practices for switchboard cabling, ensuring stability in multi-arm forms spanning mounting plates. A typical visual of a 10-cable bundle secured with the Kansas City stitch against a bulkhead features a flattened profile achieved through cascading hitches that wrap and lock the around the group and support structure, providing a low-profile hold with stitches spaced every 100-150 mm for rigidity without bulk. This method, an alternative to the Chicago stitch for large bundles, is illustrated in rack installations where it lashes cables flat to metallic frames. In modern environments, fiber optic looms are occasionally laced using Teflon-based tape variants of running stitches to bundle sensitive lines with minimal interference, adapting traditional techniques for high-density routing in relay rack units. This approach secures multi-fiber assemblies to horizontal arms, maintaining parallel alignment and accessibility while avoiding signal-attenuating pressures.

Standards and Advantages

Safety Standards

Cable lacing in regulated industries, particularly and , is governed by specific standards to ensure structural integrity, prevent mechanical damage, and mitigate electrical hazards. NASA-STD-8739.4A, in Chapter 9, outlines requirements for forming wires into cables and harnesses, mandating the use of lacing tape or cord with techniques such as starting stitches, running lockstitches, and closing stitches to secure bundles without stressing terminations. Tension must be applied evenly to avoid noticeable wire distortion, with spacing determined by bundle diameter—for example, no more than 12.7 mm between ties for harnesses up to 6.4 mm—and inspection criteria requiring verification of secure knots, uniform placement, and absence of damage to insulation or conductors. Federal Aviation Administration (FAA) guidelines, as detailed in Advisory Circular (AC) 43.13-1B, emphasize lacing over plastic ties in wiring to minimize chafing risks, requiring bundles to be laced tightly enough to prevent slipping but not so tightly as to damage insulation, using materials like MIL-T-43435 braided tape with and square knots spaced at intervals not exceeding 12 inches. Military standards, such as SAE AS50881 (which supersedes MIL-W-5088L referenced in AC 43.13-1B) for vehicle wiring, prioritize lacing for chafing prevention in high-vibration environments. This standard incorporates protections for composite materials in modern structures to maintain bundle stability under thermal and mechanical stresses. The IPC/WHMA-A-620 standard provides acceptance criteria for cable and wire harness assemblies in , requiring lacing or equivalent bundling methods to secure wires in harnesses, with mechanical tests ensuring compliance through pull-force verification on terminations and bundle integrity—such as a minimum 25-pound hold for certain crimp connections—to confirm no slippage or damage under load. General provisions across these standards prohibit sharp lacing ends or loose , mandating flush trimming and secure knots to avoid abrasion leading to electrical shorts, arcing, or ignition in confined or high-heat areas.

Benefits and Limitations

Cable lacing offers superior abrasion resistance compared to plastic cable ties, as the smooth, flat tape minimizes on wire insulation over time without serrated edges that can cut into bundles. This durability extends to in harsh environments, where lacing tape outlasts ties that degrade and become brittle due to UV exposure, chemicals, or mechanical stress. Additionally, lacing allows for easy rework, enabling adjustments or removals by untying knots without leaving residue or requiring full replacement of fasteners, unlike adhesive-backed or molded ties. Its aesthetic neatness stems from uniform, low-profile bundling that eliminates protruding tails or bulky heads, providing a professional appearance in visible installations. In extreme conditions, cable lacing demonstrates robust performance, with materials like Nomex-rated tape enduring temperatures from -65°C to 260°C while resisting fuels, oils, and abrasion. For weight-critical sectors such as , lacing reduces overall bundle size and mass compared to bulkier cable ties, contributing to lighter harnesses without compromising security. This makes it cost-effective for low-volume production, where the inexpensive, versatile tape offsets initial labor costs through long-term reliability and minimal material waste. Standards like -STD-8739.4 emphasize lacing for its ability to provide continuous support, preventing wire slippage and abrasion in high-stakes applications. Despite these advantages, cable lacing is labor-intensive, requiring more installation time than quick-snap cable ties, particularly for complex bundles. It demands skilled workers proficient in knotting techniques to ensure uniform tension and avoid damaging insulation, which can increase training needs. As such, it is not ideal for temporary setups or high-volume assembly lines, where speed and simplicity outweigh durability. Cable lacing should be avoided in or scenarios, where faster alternatives like zip ties suffice despite shorter lifespans.

References

  1. https://s3vi.ndc.nasa.gov/ssri-kb/static/resources/nasa-std-8739.4a.pdf
  2. https://www.thebroadcastbridge.com/content/entry/12400/the-lost-art-of-lacing-cable
  3. https://cdn.techflex.com/assets/pdfs/archive/lacing-tape-brochure.pdf
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  7. https://books.google.com/books?id=oN8DAAAAMBAJ&pg=PA550
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  13. https://standards.nasa.gov/standard/NASA/NASA-STD-87394
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  17. https://www.cabletiesandmore.com/nylon-lacing-tape
  18. https://buyheatshrink.com/braided-sleeving/lacing-tapes-and-cords
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  20. https://www.cabletiesandmore.com/nomex-lacing-tape
  21. https://www.techflex.com/lacing-tape/braided-nomex-lacing-tape
  22. https://assets.unilogcorp.com/267/ITEM/DOC/Ludlow_D1006_9PLY_Catalog.pdf
  23. https://jonard.com/jic-287-cable-sewing-needle
  24. http://pkneuses.com/www.pkneuses.com/cabll.htm
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  26. https://www.telephonecollectors.info/index.php/browse/document-repository/gsps-gen-tel/256-division/3466-gsp-256-050-204-i6-telephone-operations/file
  27. https://mathscinotes.com/wp-content/uploads/2014/01/021c99s2c08.pdf
  28. https://avm-mag.com/dmcs-lacelok-cable-lacing-fasteners-receive-military-qualification
  29. https://www.scribd.com/document/355347322/MIL-T-43435-Typ-1-Lacing
  30. https://www.navsea.navy.mil/Portals/103/Documents/SSRAC/NSI/FY25/009-73_FY25_PKG.pdf
  31. https://www.facebook.com/groups/ElectronicParts/posts/2620841401438512/
  32. https://www.simcona.com/blog/control-panel-wiring
  33. https://www.rdswire.com/wire-harness-accessories/mil-t-43435
  34. https://www.pegasusautoracing.com/productselection.asp?Product=4041
  35. https://fulltrackproductions.com/service%20bulletins/Complete_guide_to_cable_lacing.pdf
  36. https://www.faa.gov/documentlibrary/media/advisory_circular/ac_43.13-1b_w-chg1.pdf
  37. https://www.sae.org/standards/content/as50881h/
  38. http://www.aeroelectric.com/Reference_Docs/Mil-Specs/Mil-W-5088.pdf
  39. https://dmctools.com/lf2-na1-white-lacelok
  40. https://news.ycombinator.com/item?id=20582844
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