TECH: Make your own custom length cables

I stole/modified this idea a bit, and it works fuckin great. Would have never thought to try it, so thanks to the OP. I used odyssey bmx brake cables, which are badass for bmx bikes. For the ferrul, I used a Allen bolt, cut the head off, drill a hole in it, slide the cable in and mig weld it. Used a flap disc to get the ferrul down to size. Been running duel throttle cables and clutch like this for a while, without problems. Thanks again OP. I was goin nuts tryin to find the right length cables.

they do make a couple different solders 50/50 is half tin ,half lead ,also 60/40 60% tin 40% lead the higher the tin content the stronger ,and harder for it to pull through...commercial plumbing cant use 50/50 because of lead poisoning issues probably some EPA regulations ,probably cant get it in california cause everything causes cancer or birth defects in cali .its not noticibaly different to use obviously it will take a few extra degrees to melt but propane still works.the wedge is what does the trick but a stronger wedge is preferable

Thanks Sumo for posting this.

I've been saving up for a new set of shorter cables,(I'm running a set of flat track bars now.) and now I can

put that $ toward so other mods.

Thanks again and ride smart.

Thanks for this idea, Sumo! Fixed my throttle cable. I'd have never thought to fix it this way.

that beats the hell out of the little allen set screw units I've used in the past. My build is going to have cable clutch, rear brake, and dual throttle, so you just save my wallet some strain.

You just have to be careful not to get solder down the cable because it will make it hard and brittle. a little goes a long way. Also roughing up the hole with a tiny dremmel bit will probably help the solder bite into the cable end.

no worries

no need to rough anything up - you are putting a wedge of solder inside the cable this way. it cant come out even if it wasnt stuck to the nipple [which it will be anyway]

and yep - solder down the cable will give a brittle spot that you dont want

oh yeah bigger apes here i come lol good write up man

Awesome info. Thanks for posting it. Any thoughts on the technique in this video? ... it's certainly simple and seems like it would be strong...

The relevant bits are from 6:30 onward.

looks like a long winded way of not getting the job done right to me. i guess it would work at a pinch but for the $1 saved i would do it right and get a cable end that is actually round and will move freely in the lever recess

I hear ya. Could probably take some time to shape it properly but for what it's worth I'll end up doing mine the way you posted.

Anyone have a line on stainless braid conduit for these homemade cables? I think that would just about make this method perfect!

http://www.acehardware.com/product/i...629278.2629346

will this solder work???

Originally Posted by desertw0lf

Anyone have a line on stainless braid conduit for these homemade cables? I think that would just about make this method perfect!

Hi desertw0lf,

I was alerted to this post via Google so I joined up in order to respond to your message. There is actually a resource for cable kits with braided conduit, Venhill, which has been mentioned already in this thread, but what hasn't been mentioned is that Venhill is making a push into the US, via Venhill USA. I'm Chris, and I'm responsible for the Venhill USA effort.

I just joined up and added some information about our cable kits to the Classifieds section, including details about the contents of each kit, pricing, etc. Have a look and let me know what you think, if you have any questions, etc.

Thanks!

Chris
Venhill USA

Originally Posted by pineapplepower

http://www.acehardware.com/product/i...629278.2629346

will this solder work???

That's flux, not solder.

Here's what you need. http://www.amazon.co.uk/Draper-Exper.../dp/B0001K9QK4

If you want to buy from your local Ace, go to the nearest Ace and tell an employee you need K60/40 tin/lead solder.

I'll guess I'll give this a whirl.

aren't clutch cables stainless steel? i have some flux that is made for soldering stainless. i got it from a company that makes stainless flashing for commercial buildings. how would that work?

Figured I'd post this here since its relevant.

I got a new throttle, cables, and VMs from MMM at 650central as well as the cables to go with it. After installing everything and trying multiple ways to route the cables, I've come to the conclusion that the housing on the cable (carb side) needs to be cut back about 1/4" because its preventing the slides from dropping all the way. I've tried using my diagonal cutters to trim it back but I feel like its going to cut the wire. What would y'all suggest to cut it back?

Originally Posted by austintylerr

Figured I'd post this here since its relevant.

I got a new throttle, cables, and VMs from MMM at 650central as well as the cables to go with it. After installing everything and trying multiple ways to route the cables, I've come to the conclusion that the housing on the cable (carb side) needs to be cut back about 1/4" because its preventing the slides from dropping all the way. I've tried using my diagonal cutters to trim it back but I feel like its going to cut the wire. What would y'all suggest to cut it back?

dremil and a steady hand.

Originally Posted by SamHain

dremil and a steady hand.

Well I don't have much to lose seeing as it already doesn't work...