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sumo
08-05-2009, 5:55 AM
figured id share this here - i agree we need more tech / build stuff - only one way thats going to happen - we post it....

a friend of mine asked me to show him how to make up cables so he didnt have to either pay out for custom cables or have yards of spare on his bike.

its fairly self explanitory, but like all stuff - if nobody has ever told you then its a black art.

i buy the longest universal cables available and cut em down [specific brake or clutch, get the right thickness]

solder and bakers fluid - dont use fluxcore its not upto the job
http://i71.photobucket.com/albums/i153/banjodave/100_0815.jpg

use a propper old fashioned soldering iron not a pissy little electric thing
http://i71.photobucket.com/albums/i153/banjodave/100_0806.jpg

feed the cable through the nipple and splay the ends out so i cant fall / pull out
http://i71.photobucket.com/albums/i153/banjodave/100_0809.jpg

heat from the side with the soldering iron - for this job you dot need to put solder directly onto the iron
http://i71.photobucket.com/albums/i153/banjodave/100_0811.jpg

sumo
08-05-2009, 5:55 AM
drop in some bakers fluid down the splayed end - if it bubbles brown then your cable is dirty and needs cleaning thorougly [just heat it on the iron and dip it in bakers fluid, repeat untill clean bubbles] or your soldering wont be strong enough. feed in solder down the hole till it fills up and you can see a tiny little bit out of the cable end of the nipple [ok so im running out of hands so you get the idea
http://i71.photobucket.com/albums/i153/banjodave/100_0813.jpg

dress off with a file and there you have it - one new cable to your exact length. done like this you end up with a wedge of solder inside the wire itself. basically means you cant pull it out through the smaller hole
http://i71.photobucket.com/albums/i153/banjodave/100_0816.jpg

can save a small fortune over time doing this yourself in a safe way.

NITRO
08-05-2009, 6:47 AM
Awesome tech man! Thats something we can all use!

CaptainBob
08-05-2009, 7:05 AM
Good stuff, Sumo.

This is a case where its actually easier done than said.

sumo
08-05-2009, 7:16 AM
Good stuff, Sumo.

This is a case where its actually easier done than said.

exactly - get the right materials and have them in stores and you can have your custom cables done in 15 minutes. saves time and money

independentrider1
08-05-2009, 8:35 AM
What kind of solder is that? its not electrical or plumbing is it? any special tips on cutting or prepping the housing? this was very usefull to me. Thanks

sumo
08-05-2009, 9:12 AM
What kind of solder is that? its not electrical or plumbing is it? any special tips on cutting or prepping the housing? this was very usefull to me. Thanks

the cable outer - i just put in vice and cut with angle grinder. that way you dont make a mess of it bending it with wire cutters or something. nice clean cut every time. with the universal cable kits you get cable ends to push on as well as a selection of nipples

bakers fluid - http://www.fernox.com/?cccpage=bakers_no_3_soldering_fluid&sub=9

dont know where you will get it in america but its readily available over here in england. above is the link to its spec. search from america and google will probably find it for you. from here it just tells me nearby shops

independentrider1
08-05-2009, 12:08 PM
thanks man! I paid Barnett $50.00 plus to make a really short one for my foot clutch. Never again I'll do it myself.

BoomBoom
08-05-2009, 12:13 PM
This is excellent. Once again, one of those things that seems so simple everyone should have thought of it but most of us never do. Thanks for posting with the pics. This is the type of stuff that makes a forum great!

CECNC
08-05-2009, 4:01 PM
Great job, thanks

H34TH3N
08-05-2009, 7:57 PM
Excellent post man, been wanting to try this for a while now, glad to see how it works...Thanks

Magickman
08-05-2009, 8:02 PM
I am curious what you do with the end of the protective covering?

superflysnow
08-05-2009, 9:24 PM
so is the cable a cable kit or are there resources for the cables, outers and ends?

sumo
08-06-2009, 12:08 AM
i use venhill over here - known good quality and pretty cheap

http://www.venhill.co.uk/Cable_kits_and_components/CABLE_COMPONENTS

but again im sure there is an equivalent supplyer over there

as for the ends of the covering - thats what the ferrules are for - just push them on


although you can buy kits and for your first couple of cables its probably a good bet - that way you get a stock of various sized nipples / spare ferrules etc built up

WayneBallard
08-06-2009, 1:22 AM
Great post Sumo.

mplsdave
08-06-2009, 9:15 AM
wish i had seen this about three weeks ago when i was deciding how to fab a rod for my rear brake. would have given me the idea to make a cable myself.

Boylecomm
08-06-2009, 11:05 AM
US cable kits

http://www.flanderscables.com

http://motionpro.com/motorcycle/partno/01-0055/

Stubs
08-06-2009, 1:30 PM
I knew it couldn't be to hard but had know idea how to do it. I was way off on how to do it. Awesome post. Will be using this for a throttle and foot clutch cable.

Metalismo
08-06-2009, 7:14 PM
Great info! I was wondering how I was going to change out the dorky bars on my Sporty. Thanks guys!

heretic
08-07-2009, 9:24 AM
What kind of solder is that? its not electrical or plumbing is it? .....

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.

sumo
08-07-2009, 9:48 AM
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

glorydays
08-07-2009, 11:25 AM
Alright ,how the hell do i know what size ferrule to buy for my harley 4 speed cable?

sumo
08-08-2009, 12:47 AM
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?

sickboi55
08-09-2009, 9:18 AM
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.

glorydays
08-09-2009, 2:36 PM
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!

BlueCollarMoto
08-09-2009, 2:53 PM
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.

mjasen10
08-10-2009, 1:06 PM
great article, never thought itd b that easy

KawiDave
08-14-2009, 5:47 PM
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.

SDJose
08-14-2009, 6:31 PM
Thanks for sharing some tech knowledge. Very valuable.

Nigel
08-14-2009, 7:32 PM
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?

sumo
08-15-2009, 1:30 AM
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

oildevil13
09-01-2009, 11:24 AM
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.

pangeaspeed
09-23-2009, 10:22 PM
great article, this makes perfect sence.

junkyard2
09-26-2009, 1:56 PM
thank you for the info

turtle
01-28-2010, 12:39 AM
learn something new every day!

wilber1191
01-28-2010, 9:14 AM
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.

NHMike
01-28-2010, 9:22 AM
I'm ordering some new cables today and will be putting this thread to use. Thanks.

slumchop
01-28-2010, 7:51 PM
i like that, i always did mine with a solder pot though, gonna try it this way next time i do some cables.

Punkskalar
03-01-2010, 2:45 PM
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...

djturnz
04-13-2010, 8:07 AM
I don't have an old fashion soldering iron. Can I just use the same propane torch I used to solder copper pipe?

garbage
05-18-2010, 9:56 AM
5297
it fuckin worked!

Sighless
07-09-2010, 9:43 AM
Alright, I'll be doin this after work.

Update:
I'll be damned, it works good. and here I thought I'd be bikeless for the weekend.

wayfastwhitey
08-24-2010, 8:26 AM
very good sir!!

ARBY
09-01-2010, 10:41 AM
Is the use of the soldering iron mandatory or can I apply heat directly to the nipple???

killkill
10-19-2010, 4:25 PM
anyone have any other ideas as to where to get cable supplies? maybe around the PA area?

Bret
10-31-2010, 10:57 AM
Very helpful. Thanks!

cuttin
12-08-2010, 11:44 AM
I love to see people sharing Ideas and method. This site is the best.

JakesCustoms
12-08-2010, 2:04 PM
never thought of that i will have to start using that trick

deadbeat89
01-13-2011, 12:59 AM
cool man did it actually last?

johnnyboy666
01-13-2011, 1:06 AM
yeah man thanks for the info!

Wayland137
01-14-2011, 5:06 AM
Very helpful, thanks for the tip - screw J&P!

SoNorthCustoms
03-10-2011, 8:32 AM
So what are you guys doing for lube on these cables when you build them? I'm assuming they need something, right?

sumo
03-10-2011, 11:06 AM
i buy cable outer with a nylon liner and just use any old light oil on the cable

SoNorthCustoms
03-10-2011, 11:28 AM
i buy cable outer with a nylon liner and just use any old light oil on the cable

Nice. I'm going to mock up some bars this weekend and get a better idea of cable lengths. Thanks for the awesome how to!

MegaDON666
03-10-2011, 12:16 PM
Anyone got a line on cable Ferule's? I dont want to pay $80 bucks for Barnetts kit

SoNorthCustoms
03-10-2011, 2:05 PM
Anyone got a line on cable Ferule's? I dont want to pay $80 bucks for Barnetts kit

Looks like everything is available from the site that was listed earlier in the thread: http://www.flanderscables.com/

panmaster
03-15-2011, 4:07 PM
ive used this method with the bakers flux , and lead free solder and it works great ! i also use brass pen ink inserts ( from OLD pens ) cut down to 1/8 - 3/16 pieces to replicate the small barrel ends on triumph / british cables , the cable eventually breaks but the solder joint does'nt just my .02

fxrjocky
03-18-2011, 8:49 AM
after looking at both sights posted earlier looks like flanders might be a little cheaper. But all their stuff is listed by part number once you look at buying kits. what are you guys using to measure your cable thickness? a micrometer or something similar cause i'm about to take off my tbars for a set of apes just for shits and giggles and wanna make my own cables

ClassicCust0ms
06-14-2011, 7:14 AM
killer thread. i made my cables last night. i used my factory cables and spun new barrels on my POS harbor freight lath. spent zero bucks.

wpiken
06-22-2011, 7:29 PM
Thanks Sumo. Made a foot clutch cable instead of solid linkage for the old shovel. Used solid core solder and some liquid flux from the farm supply store I had sitting on a shelf for years. Sorry, couldn't read the brand on the flux anymore, Golden-something or other. Cost next to nothing...
(BTW the cable came from an old hang glider)

vnygra
07-01-2011, 9:40 PM
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.

some1else
07-09-2011, 9:16 PM
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

RmFaster
08-11-2011, 9:27 PM
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.

Motorradfahrer
09-12-2011, 10:39 PM
Thanks for this idea, Sumo! Fixed my throttle cable. I'd have never thought to fix it this way.

CarpeNoctem
09-16-2011, 9:39 AM
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.

sumo
09-16-2011, 9:47 AM
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

zero937
11-02-2011, 1:26 AM
oh yeah bigger apes here i come lol good write up man

Gusto
02-09-2012, 1:03 AM
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.

<iframe width="420" height="315" src="http://www.youtube.com/embed/F-gY27LTU2c" frameborder="0" allowfullscreen></iframe>

sumo
02-09-2012, 6:09 AM
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

Gusto
02-11-2012, 11:22 AM
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.

desertw0lf
02-23-2012, 8:27 AM
Anyone have a line on stainless braid conduit for these homemade cables? I think that would just about make this method perfect!

pineapplepower
04-17-2012, 7:45 PM
http://www.acehardware.com/product/index.jsp?productId=1290594&cp=2568443.2568450.2628094.2629278.2629346

will this solder work???

venhillusa
05-14-2012, 1:45 PM
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

Pendulum
05-14-2012, 2:39 PM
http://www.acehardware.com/product/index.jsp?productId=1290594&cp=2568443.2568450.2628094.2629278.2629346

will this solder work???

That's flux, not solder.

Here's what you need. http://www.amazon.co.uk/Draper-Expert-19226-Solder-1-2mm/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.

MeanBean
06-07-2012, 10:31 PM
I'll guess I'll give this a whirl.

TimB1640
08-03-2012, 7:29 PM
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?

austintylerr
03-28-2013, 4:29 PM
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?

SamHain
03-28-2013, 6:24 PM
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.

austintylerr
03-29-2013, 7:29 AM
dremil and a steady hand.

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

13clicks
11-19-2013, 6:24 PM
killer thread. i made my cables last night. i used my factory cables and spun new barrels on my POS harbor freight lath. spent zero bucks.

Photos?

meathead75
11-21-2013, 2:44 AM
I put 20 inch apes on my bike and uses a set of push pull cables from venhill usa. Ordered the longest generic cables they had and got lucky i didnt even have to cut them but maybe two inches. I think the whole deal cost like 35 bucks which was a way better deal than anywhere else. They even sent me an email telling me when they shipped and when they would arrive. After i got them they sent me an email asking if i liked them and asked me to recomend them and contact them if i had any problems. Real good to deal with. When i soldered on the ends i drilled a real big hole in a 2x4 covered the hole in flux and than melted the solder into that. I also split the ends of the wire after i had them through the thing and than dipped it in that puddle of solder. Worked real good. Than i grinded the extra solder off and that waz it. Much easier than i thought it would be. And way cheaper too. No problems so far and that was like 3 months ago.

vnygra
11-21-2013, 8:16 AM
I get cables at the Honda dealership by my house. They have a generic cable they can order. They cost $1.99. One dude knows me and knows what I'm looking for, some of the other dudes think I'm nuts asking for a generic throttle cable, but it is in their part book. Just gotta get em to find it.

XLJeh
11-22-2013, 11:45 PM
I get cables at the Honda dealership by my house. They have a generic cable they can order. They cost $1.99. One dude knows me and knows what I'm looking for, some of the other dudes think I'm nuts asking for a generic throttle cable, but it is in their part book. Just gotta get em to find it.

You should grab the honda OE part number on this I wouldn't mind looking into it. The dealer here has a new parts guy every week with less and less exp. I usually look up my own numbers and just give it to them and review them in the order too.

chopedone
11-23-2013, 8:22 AM
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?

For this I've used a small tubing cutter, available in the plumbing section of home supply centers, hardware stores, or even a good auto supply store will have 'em.Works like a charm!! Didn't fray ONE strand of the inner cable... Hope this helps...

KingHerald
12-06-2013, 11:32 AM
I need to make a tiny nipple for the carb end of my throttle cable. I'm think something like 1/8" welding rod with a tiny hole drilled in it might work. The nipple is the opposite way round to most every clutch or brake cable I've seen.

I've checked in all the local bike shops, but nobody has anything like it.

Carb is a Mikuni, where the cable feeds through the screw on cap, then through a small hole in the slide, and slips into a slot to hold it.

Choppasaki
12-19-2013, 7:31 PM
measure it....
you can also make the cable end with a fishing weight makin' kit and a hand made mould, most are lead anyway, but I like the idea of using brass ferels and solder.

685
04-01-2014, 8:46 AM
Thought I'd pop in and post a thanks for this thread. I found it Googling cable ends.

I'm putting CVK 40mm carbs on an old BMW 900, bored to 1050, and needed to adapt some KLR choke and throttle cables. Kawasaki's KLR 650 uses the same carbs, minus the accelerator pump as Harleys. I found my two carbs & all 4 of the cables for under $200.

Flanders is a great resource, I got all my bits, both ferrules and cable ends for about $10. I managed to get my sizes right the first time--a digital micrometer from Harbor Freight helped. For those who haven't dealt with Flanders, they do offer individual parts--that was a little confusing to me, they list bags of 25, too. But the good part is there's no need to buy massive collections of cable parts in one of those huge motion-pro kits. Flanders calls to check your order before they ship, and there is a small $2 charge for orders under $20. Shipping was fast, ordered Thursday, shipped Friday, in my mail box on Monday.

It looks like a product called Ruby Fluid will do the job of getting the solder to stick to the cable. http://rubyfluidflux.com/Soldering_Flux.html I'm hoping the local plumbing supply store stocks it, if not Do-It-Best associated hardware stores do. And McMasters-Carr. And Amazon. Small containers--less than $5.

Again, thanks to the OP and all the other contributors to this thread. It's helped me whole lot.

685
04-01-2014, 8:56 AM
I need to make a tiny nipple for the carb end of my throttle cable. I'm think something like 1/8" welding rod with a tiny hole drilled in it might work. The nipple is the opposite way round to most every clutch or brake cable I've seen.

I've checked in all the local bike shops, but nobody has anything like it.

Carb is a Mikuni, where the cable feeds through the screw on cap, then through a small hole in the slide, and slips into a slot to hold it.

I have a set of those carbs, mine are VM38s. You can get the right cable end from Flanders, the p/n is 620-24749. 64 cents each plus shipping and a $2 surcharge. The ferrule to finish off the end of the outer cable is called a Derby ferrule, p/n 620-20920, 96 cents ea.

CHEN
04-29-2014, 11:37 PM
I'm having a hard time finding some Bakers Soldering fluid over here in the US. Any good substitutes? What am I looking for in the flux that will work for this application?

BrokenFang
06-02-2014, 5:48 PM
have question about brake and clutch cables. should i do the end at the lever or the other end on these cables. i am cutting stock ones down.

SNOT275
06-03-2014, 1:00 AM
I'm having a hard time finding some Bakers Soldering fluid over here in the US. Any good substitutes? What am I looking for in the flux that will work for this application?

Would like to know this too

BrokenFang
06-09-2014, 5:34 PM
Flanders cables has the equivalent to bakers. i just orderd that and some ends from them the other day

Paris
04-24-2015, 6:19 PM
As far as flux to make the cables. Oatey #5 solder paste. They sell it in any hardware/homedepot in my part of the country. Now onto my cable problems. I bought a generic throttle and clutch cable from venhill us. I haven't done much with the throttle cable but it looks like it is going to work out great. The clutch cable is a different story. The generic clutch cable kit from venhill is to small a diameter and none of the cable ends are the correct size for my application. Which I should have started with. 1979 fxef. I got rid of the stock clutch lever and bought one off ebay that came from a 95 fx. I looked around and cannot find a cable end that goes on the lever end. So I either have to a) go with a stock shovel clutch lever. I'm not going to do this because I don't want the built in button housing. B) Order a lever for a panhead. This look like my best option. Or c) buy a random Honda clutch lever, bore it out to fit 1" handelbars, and then hope I can get the cable parts to make it work. I realy want to make my own cables. I have been racking my brain trying to figure out the correct combo of cable, conduit, cable ends, and ferrules to buy. I calls Flanders today to try and get some expert help. I was told they could send me parts but I would probably get the wrong ones and be upset. They did say they would be more than happy to make me a clutch cable All I had to do was ship them my old cable and new clutch lever and tell them how much longer I wanted it and they would make it and send everything back. So if any one can point me in the right direction... Is the cable a 2.5mm or a 3mm. If it is 2.5mm do I use the 6mm or 7mm conduit. The trans end of my cable has a lead ball that measures 7.6mm. What cable end fitting would I get from Flanders to replace the ball. I don't have the pan clutch lever yet so I can't measure anything but I will need a cable end and a ferrule that fits. Any ideas? Also. If I'm gonna buy cable makings I would have enough left to make a few more cables. I would like to make some for friends with stock shovel setups that just need longer cables. What ferrule/cable end would I get for the lever side of the cable. I can't seem to find exact replacements in the Flanders catalog. Ughhhhhhh. So frustrating. Sorry if this post is erratic and hard to follow. My frustration is getting to me. Any body with any info on any of this would be appreciated.

Freewheeler
04-25-2015, 1:30 AM
Good post Sumo,

I need to make up some longer cables and have been itching to have a go at making my own - thanks for the Fernox link.

Nick

BlackCloudSalvage
04-25-2015, 12:19 PM
Awesome. Thanks for sharing

Sal
04-25-2015, 10:00 PM
Finaly seeing a decent cable building kit including sheathin and a decent end assortment on the market place now

Motocrash
06-01-2015, 6:47 AM
As far as flux to make the cables. Oatey #5 solder paste. They sell it in any hardware/homedepot in my part of the country. Now onto my cable problems. I bought a generic throttle and clutch cable from venhill us. I haven't done much with the throttle cable but it looks like it is going to work out great. The clutch cable is a different story. The generic clutch cable kit from venhill is to small a diameter and none of the cable ends are the correct size for my application. Which I should have started with. 1979 fxef. I got rid of the stock clutch lever and bought one off ebay that came from a 95 fx. I looked around and cannot find a cable end that goes on the lever end. So I either have to a) go with a stock shovel clutch lever. I'm not going to do this because I don't want the built in button housing. B) Order a lever for a panhead. This look like my best option. Or c) buy a random Honda clutch lever, bore it out to fit 1" handelbars, and then hope I can get the cable parts to make it work. I realy want to make my own cables. I have been racking my brain trying to figure out the correct combo of cable, conduit, cable ends, and ferrules to buy. I calls Flanders today to try and get some expert help. I was told they could send me parts but I would probably get the wrong ones and be upset. They did say they would be more than happy to make me a clutch cable All I had to do was ship them my old cable and new clutch lever and tell them how much longer I wanted it and they would make it and send everything back. So if any one can point me in the right direction... Is the cable a 2.5mm or a 3mm. If it is 2.5mm do I use the 6mm or 7mm conduit. The trans end of my cable has a lead ball that measures 7.6mm. What cable end fitting would I get from Flanders to replace the ball. I don't have the pan clutch lever yet so I can't measure anything but I will need a cable end and a ferrule that fits. Any ideas? Also. If I'm gonna buy cable makings I would have enough left to make a few more cables. I would like to make some for friends with stock shovel setups that just need longer cables. What ferrule/cable end would I get for the lever side of the cable. I can't seem to find exact replacements in the Flanders catalog. Ughhhhhhh. So frustrating. Sorry if this post is erratic and hard to follow. My frustration is getting to me. Any body with any info on any of this would be appreciated.

I'm using a Honda clutch lever on my build and 7/8" bars. I bought a cheap clutch cable off ebay for Harleys and made my own end to fit the Honda lever out of the unthreaded part of a long steel bolt. I used two drill bits in my cheapo HF drill press to make the hole. I spent less than $20 per cable. The cables are closer to 3mm (.110) and have a 7mm conduit (sheath?).
If you are using a Harley lever, does it use the banjo (loop) looking fitting? If so, maybe your local HD dealership can give you an old trashed cable and you can de-solder the end off. Or maybe check some HD forums for a broken one? Or, buy a cheap cable with your lever fitting, and make (or buy) the tranny end ball. I'd buy a ball end that's the right diameter with a smaller hole and drill it to fit.
BTW, I don't think Oatey's No.5 will work on stainless cables.

If you have any Q's, feel free to PM me, I may be able to help out.

Bottom Feeder Solder Pot:
http://i232.photobucket.com/albums/ee110/Apelike1/Botton%20Feeder%20Solder%20Pot_zpszuehvpid.jpg (http://s232.photobucket.com/user/Apelike1/media/Botton%20Feeder%20Solder%20Pot_zpszuehvpid.jpg.htm l)

1" pipe cap (de-galvanized with muriatic acid). Dip you knip in flux, dip in pot. I heat it with my handy-dandy bernzotorch. :)

Edit: scroll to bottom of page (Honda-Davidson clutch cable). :)
http://www.chopcult.com/forum/showthread.php?t=19594&page=7&p=673846&posted=1#post673846

IchibanMoto
09-24-2015, 7:15 AM
excellent tips !

I have been cutting and fitting ends like this:


https://www.youtube.com/watch?v=FzARBO7Zcnc

gray
09-24-2015, 9:32 AM
excellent tips !

I have been cutting and fitting ends like this:


https://www.youtube.com/watch?v=FzARBO7Zcnc

Good to see you posting here. I'm a big fan of your tutorials.

35flathead
09-24-2015, 11:46 PM
wait... dude just melted a louded round above an open flame......... am i missing something here or is that gun powder going to fall into that lead and possibly ignite!? also thats a copper jacket round wtf?