How to make custom length control cables.

Anyone who has tried to swap out the XJ hand controls with 1" (like HD) knows the headaches of finding clutch and throttle cables the are correct lengths (they don't exiast...anywhere!) So I took my new and too long cable to the only guy in town who makes cables, he couldn't do it because the cable was "too large in diameter for what I have". He suggested getting a cable clamp from the hardware store. Yeah, that'll look real professional on my project. NOT

So I had an idea how I could make the cable myself as I sat in the garage contemplating the past week (car blew the motor, communications board went out on my cnc, 32inch LCD tv died...unemployment runs out.. 8O )


Grabbed a small block of 1/2" scrap steel and drilled a 19/64 hole all the way through it. Clamped that on top of another piece of scrap steel



.....and then grabbed my propane torch.



I then took an old junk cable I had lying around and began heating the end of the cable with the 'nub' on it (don't know what the official name is for them) Once it got hot enough I was able to to 'drip/drag' it into the 19/64 dia hole. I did that with a total of 3 cable ends. Then I patiently heated the small block of steel around the hole with the melted solder in it. Once it was sure it was completely melted (I stirred it with a small nail held by pliers) I inserted my trimmed cable into the mix I heated the cable a little before and after inserting it so the solder would get good penetration around the steel strands of the cable.




I held it there for 2-3 minutes while it solidified, then I ran cool water over the whole thing. Then I unclamped the small block and took it to my vise to drive the part out of the block




I ended up using a bolt that was just the right diameter to drive it out.

And here it is...looks as good as the real thing!

 

They call that a solder-pot in the cable-making biz, very elegant and efficient solution you have there!

 

I love this! Also, what kind of cnc is it?

 

what cable uses that type of end?

I cut down my clutch cable and tried forever (till midnight) to drill a small hole in a 1/4 bolt so i could jb it in there... i said f it and made a clamp..


is there a way to make one where the cylinder of lead is the opposite way, like in the clutch cable and throttle?

also- it's too bad they cut unemployment for good, honest people like you...


why dont you pm me your engineering credentials, as alum of my fraternity are always emailing the list of people looking for experienced engineers... I believe there is someone looking now in Cadillac...

 

Scooter, that's the clutch cable on the motor end. To do it 90 deg opposite could be done but would require drilling a hole through 2 plates and cutting a groove where the cable would go on the face of each plate. Clamp the whole business together and the drop in the solder.

Hasersys, it's an old Dynapath Delta 20 controller. The MTB Interface / Communications board isn't communicating

Thanks Scooter, but I am getting out of my current trade and going back to school in the health care field. Only have 1 more year to go can you say 401k withdrawal?? lol

 

it's a good idea to use acid flux when soldering steel, i don't see any solder wicking up the cable, watch that one for awhile it might pop off
schooter: start with a cylinder the right size, drill a hole through the side for the cable, counter sink one side, slide on the cylinder and braze on a little ball of brass to the tip of the cable, ball fits in countersink and Schooter goes riding
it's a good thing you failed with the jb weld

 

I may have to steal this from you and do it when I get to that point of my build. Awesome thanks. I thought I saw some where on the web of some one who was making custom lengths on cables. I can't remember where I saw it. It may have been the brake lines though.

OH, I see. That is a serious cnc. I am building one after my bike is done. I had build a driver board but after testing it I realized I want to make a bigger cnc. The first board I built would only run small steppers. I figure I might as well build a nicer version of it. I wish I had a machien shop.. I work in a Huge shop but do not get to use the tools for personal use. Well only when I sneak the work in lol.

 

Polock spotted a potential problem for you with that Cable-end job.

Before you placed the end of the wire into the molten lead ... you should had brushed some Flux onto the Wire and "Tinned" the end with Solder.

Then, after pre-heating the Solder in the Mold ... Applied heat to the end of the wire until the Wire end became molten and inserted the Wire into the Mold letting the Heated Wire transfer the heat to melt its way into the Form.

Then, the lead in the Form runs to the Heat Source through Capillary Action, and the entire area "Saturated" with the molten lead and permanently bonded.

Not what is referred to as a "Cold connection" where the molten lead in the Form adhering to just the outside surface of the cable strands.

If it's a Cold joint ... it might get pulled-off.

 

that's what i was trying to do, polock, but our drill press is a low rpm made for large holes, and the drillbit would just bend and wouldnt stay in the middle, one time i got it to bite after i flattened the surface, but thn i managed to cut at an angle and blah blah, i may look at the hardware store for something small with a hole in it or something...

 

You had the right idea, Schooter, much easier than lead bullets, but don't use a high tensile bolt & use sharp drill bits.

 

"i may look at the hardware store for something small with a hole in it or something..."
i ain't sayen nuttin

 

Try the Korean place on the corner (!)

 

bwa hahahah

 

:facepalm:

 

Schooter:

You may very well find EXACTLY what you need if you look for what they have available on this site:

If you need a Cable
Part of a Cable
Something ... "Cable Related"

Here you go kid.
I'm giving you the Hook-up.

EVERYTHING to "Make your own Cables"

http://www.scooterdomain.com/gas_scoote ... ?Click=115