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.
* 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.
the Condor BOTY 2011
Ol' Sparky BOTM Dec. 2011
Lucky #13 BOTY 2018