Cable Shortening made EZ
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- HOTT
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Cable Shortening made EZ
I, like a few others in the past few months, needed to shorten cables on my project bike. One has to search a few years back to get some ideas on how to do cable modifications (mostly repairs). Here are some ideas I used to do permanent custom length cables.
You'll need;
* 1/4" solid round brass stock (ACE Hdwr)
* 5/32", 7/64" drill bits
* propane torch with rosin core solder
* shear cut cable cutter or Dremel with cut-off wheel
After measuring (important step) the original excess cable (distance between barrel to housing), cut off barrel.
A shearing style cable cutter does the best job keeping strands together. (Use dikes at your own risk.)
Route housing with the smoothest path possible. Radical twists and turns makes for a poor or hard feel at the lever. Cut excess housing. Measure twice cut once !
Don't throw that extra housing away ! Remove ferrule with a Big Ol' Cresent wrench by turning counter clockwise.
Trim back the metal spiral flex and press on ferrule. No need to re-crimp.
With housing reduced, it's on to the barrel.
Drill an inset with 5/32''bit followed by 7/64'' thru hole in 1/4'' brass stock.
Time to re-insert cable (the correct direction). Remember that excess measurement ? Make a mark on cable were the new barrel will go. This is a good time to install the plastic bushing if your original cable had one.
With barrel & cable trimmed to to size, Fray a small amount of cable past the barrel.
Using your torch , sweat solder barrel from frayed side. Grind off frayed/ soldered excess and you are ready to re-install.
A perfect fit that won't slip. This technique works good on throttle cables also. Although I must confess sometimes I use knarps (barrels with set screws) Ric
You'll need;
* 1/4" solid round brass stock (ACE Hdwr)
* 5/32", 7/64" drill bits
* propane torch with rosin core solder
* shear cut cable cutter or Dremel with cut-off wheel
After measuring (important step) the original excess cable (distance between barrel to housing), cut off barrel.
A shearing style cable cutter does the best job keeping strands together. (Use dikes at your own risk.)
Route housing with the smoothest path possible. Radical twists and turns makes for a poor or hard feel at the lever. Cut excess housing. Measure twice cut once !
Don't throw that extra housing away ! Remove ferrule with a Big Ol' Cresent wrench by turning counter clockwise.
Trim back the metal spiral flex and press on ferrule. No need to re-crimp.
With housing reduced, it's on to the barrel.
Drill an inset with 5/32''bit followed by 7/64'' thru hole in 1/4'' brass stock.
Time to re-insert cable (the correct direction). Remember that excess measurement ? Make a mark on cable were the new barrel will go. This is a good time to install the plastic bushing if your original cable had one.
With barrel & cable trimmed to to size, Fray a small amount of cable past the barrel.
Using your torch , sweat solder barrel from frayed side. Grind off frayed/ soldered excess and you are ready to re-install.
A perfect fit that won't slip. This technique works good on throttle cables also. Although I must confess sometimes I use knarps (barrels with set screws) Ric
If we can't fix it, we can fix it so no one else can.
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- bladredhead
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Re: Cable Shortening made EZ
neato.
i've tried soldering cables on my bicycle to keep the ends from fraying and couldn't get the thing clean enough for the solder to stick. did you do anything special for cleaning?
i've tried soldering cables on my bicycle to keep the ends from fraying and couldn't get the thing clean enough for the solder to stick. did you do anything special for cleaning?
Broken 1976 gl1000... and a few others
- HOTT
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Re: Cable Shortening made EZ
Just rosin core solder. Stay away from acid core. It just makes a mess.did you do anything special for cleaning?
If we can't fix it, we can fix it so no one else can.
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- taunusrainer
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Re: Cable Shortening made EZ
I tried the same with poor results. Seems it requires a special flux to make it work. What kind of wire material is used in clutch cables etc.? Is it ss or plated steel? Plated with zinc or cad? No idea...
1976 GL1000 test mule
1977 GL1000 in parts, rebuild in progress
1969 Ford 17m 2.3V6
1976 Ford Cortina 2.3V6 (Propane)
1990 Mustang 5.0 7up conv.
1998 Peugeot 406 Coupe (Propane)
1977 GL1000 in parts, rebuild in progress
1969 Ford 17m 2.3V6
1976 Ford Cortina 2.3V6 (Propane)
1990 Mustang 5.0 7up conv.
1998 Peugeot 406 Coupe (Propane)
- HOTT
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Re: Cable Shortening made EZ
I always thought they were Stainless. I know my bicycle ones are. We solder those too.What kind of wire material is used in clutch cables etc.?
If we can't fix it, we can fix it so no one else can.
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- Whiskerfish
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Re: Cable Shortening made EZ
Very Nice!!
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"Yea I do dance awkwardly, and I am having more fun than you" Taylor Swift
2008 GL1800 IIIA "TH3DOG"
1984 GL1200 Standard
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- JBz
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Re: Cable Shortening made EZ
Thanks a lot Rick. JB
jbz........... Thinkin about sh-t too hard and You wont get anything done
- WShie
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Re: Cable Shortening made EZ
Great job. I think the main point to remember is that you must fray the end and then fill the fray with solder. The solder keeps the fray spread apart so it can't pull it through the hole.
Bill
1979 GL1000- On the road again after 19 years
1980 GS1000G Current Moneypit.. er project
1976 KZ400- Winter Project
Gone but not forgotten:
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1979 GL1000- On the road again after 19 years
1980 GS1000G Current Moneypit.. er project
1976 KZ400- Winter Project
Gone but not forgotten:
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1956 Triumph 650
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1979 Yamaha XS1100
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Re: Cable Shortening made EZ
I've soldered cables just using the same set up for copper plumbing. What I've done is drilled a hole in a board about a quarter inch deep the diameter that I needed, fluxed the cable, melted the solder into the hole then pushed the cable into the hole and let it cool worked great.
76 gl1000
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Re: Cable Shortening made EZ
Brillant! I will use this on my clutch cable, the original one pulled the cable out and split the barrel. I already ordered the new one but I can fix the old one still on the bike and keep the new one as a spare.
Phil US Army vet
Not all who wander are lost
1971 cb 350 (gave away)
2007 xl 1200 nightster (sold)
1979 gl 1000 daily driver work in progress
1976 gl 1000 under the knife, or wrench
Not all who wander are lost
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- fish
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Re: Cable Shortening made EZ
I have done this trick many times with acid core 60-40 solder.
acid core sticks to anything
I can never get rosin core to work for beans
I live waaaaay out in the country & instead of driving into town to buy brass bar stock I use the shoulder section of a 1/4" bolt. I just cut off a short section and use it instead of brass
acid core sticks to anything
I can never get rosin core to work for beans
I live waaaaay out in the country & instead of driving into town to buy brass bar stock I use the shoulder section of a 1/4" bolt. I just cut off a short section and use it instead of brass
Timothy Mark Fisher
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Re: Cable Shortening made EZ
if it doesn't stick or doesn't stick right it usually means that your not getting it hot enough. you'll know you have it right when the solder "wicks" or sucks into the cable. Flux paste or liquid will clean your parts right away and help heat transfer. Just because the solder melts doesn't mean it attached!
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77 GL-1000 nekid
77 GL-1000 nekid
- HOTT
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Re: Cable Shortening made EZ
jafo, had the same thing happen last year. The GL1000 is a PITA to change out quick so this is what I did. (overkill but fun)the original one pulled the cable out and split the barrel
http://www.ngwclub.com/forum/viewtopic. ... s+in+Texas
Now that's just good thinkin' there. Thanks fish. I really am a fan of acid core. I just have seen it corrode the surrounding repair after awhile. This was a new cable so I didn't have any dirt issues. I can see where a piece that has been in use may need a little more persuasion. Different strokes...I use the shoulder section of a 1/4" bolt
Right you are ! If you look at the photo you can see the solder actually pulled though the barrel from the frayed end to make a blob on the cable side.Just because the solder melts doesn't mean it attached
If we can't fix it, we can fix it so no one else can.
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- Roady
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Re: Cable Shortening made EZ
This is an excellent tutorial so I've moved it to the How-To for Wings forum.
Also, it's going into ShopTalk.
Well done, Hott!
Also, it's going into ShopTalk.
Well done, Hott!
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Re: Cable Shortening made EZ
Excellent tutorial...I have it saved in my C: drive of my brain.
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