DIY shortening brake/throttle cables
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DIY shortening brake/throttle cables

This is a discussion on DIY shortening brake/throttle cables within the Technical forums, part of the Caferacer.net Forums category; this came up in the projects section, and i just wanted to see hacksaw's and other peoples' ideas for shortening their cables......

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  1. #1
    Senior Member mudmonkey's Avatar
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    DIY shortening brake/throttle cables


    this came up in the projects section, and i just wanted to see hacksaw's and other peoples' ideas for shortening their cables...


  2. #2
    Senior Member HackAsaw's Avatar
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    you left out my middle A and that could start quite a bit of confusion

    but I'll see about digging up some pix for show and tell

    gotta run for now
    Accidental inventor of the worlds fastest wearing rocker arms and other edible engine parts! Try my yummy blue cheese camshafts!

  3. #3
    Senior Member ttilghman's Avatar
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    hack a-hole saw.....



    sorry, couldn't resist-
    tt

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  5. #4
    Moderator jbranson's Avatar
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    I've made up several of my own cables using stuff I got from Flanders. It's very cool once you get the stuff you need, and can solve a lot of problems.
    JohnnyB

  6. #5
    Senior Member ttilghman's Avatar
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    otherwise. cut to size, untwist the cable a bit, drip in a bunch of solder so the hardware cant back off the cable and you're good.

    -tt

  7. #6
    Senior Member pampadori's Avatar
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    quote:Originally posted by ttilghman

    otherwise. cut to size, untwist the cable a bit, drip in a bunch of solder so the hardware cant back off the cable and you're good.

    -tt
    how do you add the end back to the cable? solder surely wouldn't hold the tension. tell us more!

    i shortened a clutch cable once by cutting it and then welding the cable back together near the end where there was no insulation. but i want to know other methods. learn me!
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  8. #7
    Senior Member parks61's Avatar
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    throttles and clutches...ok to solder.
    brake cables....no way (for me).
    i only dare do a factory end for the lever and a high quality pinch barrel (two for the front) at the brake arm...(drums) you disco types are using juicey tubes...
    phil turq has a cute little cast iron frying pan in which he heats solder and tips the fluxed cable with end into. keeps the carbon (from a torch) from contaminating the chemical bond between the metals.
    -parks
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  9. #8
    Senior Member HackAsaw's Avatar
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    tigging stainless cable inners to one off stainless barrels...... totally rocks

    but even if using flanders or barnett ends.... you can pop the end of the cable with the tig for just a second

    and the cable inner will form a nifty little ball that won't pull thru

    I've yet to have one break and I even make them for my carbs

    first time I thought about what would happen if that tiny end broke off while it was running

    still rounding up pix for an album and I'll share them

    when I was wrenching in Billy Lane's shop, he shared with me his trick on doing cables with rod end joints

    done a few and they aren't bad at all but now I make them adjustable so it's a bit different

    here is one like that, usually I use stainless bolts instead of grade 8

    btw, the anchor swivels

    Accidental inventor of the worlds fastest wearing rocker arms and other edible engine parts! Try my yummy blue cheese camshafts!

  10. #9
    Senior Member ttilghman's Avatar
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    parks-

    i did the solder thing with my front brake...as spec from michael morse. there is hardware to fit the loop on the actuating arm that could never slip over the big puddle of solder i've managed to drip into the opened strands at the end of the cable....i've run it for three seasons now. including a redo when i had to shorten things up with a different drum.

    so pamp, that's it as far as i know. i've only sized my front drum cable. the cable came with the barrel for the hand lever already installed. i had to determine the length, slide some hardware over the cable (which mates to the actuating arm), and fray the end of the cable. then fill the frayed end with solder so the machined hardware(end)can't slip off the end of the cable. for a clutch, i'm thinking it would be the same depending on the hardware at the cam/pull rod.

    i'm sure some others will know some better stuff (technique&hardware).

    -tt


  11. #10
    Moderator jbranson's Avatar
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    I soldered a bunch of cables, including brake cables...that's the way they come from the factory..soldered. But...you need to use a quality brass end, fray the cable properly, dip in flux and use a solder pot (home made or otherwise). After soldering, use brake cleaner or something to make sure all the flux is cleaned off so it doesn't corrode the cable. I've tested a few, tore the cable apart before it would come out of the end ferrel.

    But...wouldn't recommend it for brake cables unless you are confident of your results.
    JohnnyB

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