TECH: Make your own custom length cables

Originally Posted by heretic

My guess is that stuff would be damn close to LA-CO N3 liquid flux. Should be able to buy it at any large plumbing supply place. You could also use standard LA-CO flux just make sure you get the stuff that is NOT water soluable.

the flanders cables link above has some for sale in its "tools" section $12

Alright ,how the hell do i know what size ferrule to buy for my harley 4 speed cable?

Originally Posted by glorydays

Alright ,how the hell do i know what size ferrule to buy for my harley 4 speed cable?

maybe im missing something here but measure it?

the listing of ferrules on the flanders site has drilled size, conduit size, OD and length

what more do you need?

i agree that it very easy and rewarding to make your own cables. although my method is a little different. i have a piece of round bar the i drilled a hole into. fill it with solder and heat it with my propane torch. then after the end is on the cable you just dip it. works for me.

Originally Posted by sumo

maybe im missing something here but measure it?

the listing of ferrules on the flanders site has drilled size, conduit size, OD and length

what more do you need?

Somebody to tell me!

Thanks Sumo! Great Tec.

I just found a article from Big Bike Magazine from Aug 1973 on the same subject this morning. I'll post it up as soon as I finish scanning stuff today. For all the writing they did in the article they didn't quite say as much as you did. Still good stuff though.

great article, never thought itd b that easy

I used to hang around the local dirt bike shop when I was ateenager. They would make custom cables for folks but I couldn't really remember exactly how it was done. You brought everything back, thanks Sumo.

Thanks for sharing some tech knowledge. Very valuable.

Fantastic!!!!!!

I have had problems with regular solder. Just lead? or is there a different composition that won't pull through? I have cleaned, and got the the solder to take well ( best I can tell) but I have had the cable pull out?

Originally Posted by Nigel

Fantastic!!!!!!

I have had problems with regular solder. Just lead? or is there a different composition that won't pull through? I have cleaned, and got the the solder to take well ( best I can tell) but I have had the cable pull out?

if you splay the ends of the cable before you solder it then it is pretty much impossible to pull it out. you are effectively putting a wedge inside the cable itself this way.

may be the flux you used was different - i only use bakers for cables not regular flux, or maybe you just didnt get it hot enough or something, maybe the cable was dirty? dont really know without seeing your setup. but done like the pics i shot with the stuff i use they are pretty bullet proof

We use the same technique to "babbit" rope socket ends on cable tools that we run up to 10,000 ft into the ground. Splaying the end of the cable is the key. Ive poured lead babbit, and in the last few years we use a compound similar, but application specific, to JB Weld.... we put a whole lot more strain on those rope sockets than you ever will with a throttle or a clutch.... even comparatively (sp?) A little brake cleaner to get the cable really clean... Great post Sumo... thanks. Its a black art until somebody tells you! Ive made a few cables for my bikes.... and I wont embarrass myself describing the completely retarded, long way around, what the fuck was I thinking methods I used. I do this kind of thing at work... yet at home I try to reinvent the wheel! Wylie Coyote was an amatuer.

great article, this makes perfect sence.

thank you for the info

learn something new every day!

Very nicet if wish I had this info about three months ago when I was making my foot clutch cable. I ended up making and using a set screw set up to secure the cable end.

I'm ordering some new cables today and will be putting this thread to use. Thanks.

i like that, i always did mine with a solder pot though, gonna try it this way next time i do some cables.

Worked really well for me. Spun the ends out of an old brass punch, used silver solder from NAPA. Looks professional, and cheap to make...

I don't have an old fashion soldering iron. Can I just use the same propane torch I used to solder copper pipe?