Throttle cable

Far easier and more reliable making cables on the actual bike, using the routing that will be used.

Even with a lot of care and consideration, I end up modifying a finished cable to make it fit as I intend.  Just giving dimensions to somebody without him/her/it knowing how the cable is to be routed will rarely yield satisfying results.  Bends can shift dimensions to the point the cable no longer fits.

I've been making my own custom cables for quite some time, they've turned out to be more reliable than bought-in ones, and fit better!  Outer and inners are available in a variety of sizes, ferrules and nipples ready to fit.  Sometimes I need to make a nipple, simple enough with brass rod in various small diametres.  Soldering is done after "bird caging" in a soft solder bath, just like in the Venhill vid.

piet
 
Vince said:
They did reasonable work, but it took 4 goes to get it right. And that was with detailed sketch supplied. They kept getting the distance between the inner and outer wrong. It's a long drive from my place to them. Maybe if you supply a sample and say just like this but X shorter. They have been doing this since WW2, I don't know why they don't have a file of sizes for specific bikes from over the years?
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4 goes :o I gave Flexi Drive I go at fixing their errors. After they came back they were closer but I had to use some spacers to take up the slack. Totally useless. I used the Perth mob.
I gave them a detailed drawing showing fittings and all dimensions as well as sending them a set of incorrect cables so they could use the fittings for either ends, I spent my life working to 0,1mm so when something comes back 10mm too long just blows me away. When they came back the 2nd time they were 5mm too long at which time I give up and deal with the issues myself hence the spacers. then the nipple broke off after a couple of thousand kays. Seriously bad workmanship.
 
motoddrob said:
When they came back the 2nd time they were 5mm too long at which time I give up and deal with the issues myself hence the spacers. then the nipple broke off after a couple of thousand kays. Seriously bad workmanship.
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The extra 5mm was to allow enough length for you to trim back to a good bit of cable and solder the nipple back on properly.  :D
 
When I was out on the north sea my son rang me - lucky as we rarely had coverage - with a broken throttle cable on his trail bike that he used to get to work. I directed him over the phone, much to his frustration, and he made a new cable, inner and outer from my Venhill nylon lined kit using the original Honda bends and adjusters. He found it hard but got it done. Any stuff like that here is an order it and wait event, either on the net or from a bike shop, if you can't do it yourself. A bit like being in outback WA.
 
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