Senior Member
Join Date: Apr 2005
Location: Minneapolis, MN, USA
Posts: 1,152
Bikes: 1990 Burley Bossa Nova, 1992 Paramount PDG-70, 1993 Specialized Stumpjumper, 2005 Jamis Dakar XC Pro, 2007 Rivendell Bleriot
Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 28 Post(s)
Likes: 0
I use the little brown cutting discs. You just have to be very careful not to push _sideways_ against the disc with the housing as you cut, or it will shatter. I think the technique that works the best, which I just came up with, is to clamp the dremel in a vise and hold the housing that you are cutting.
I use medium high speed, and very gentle pressure. I also usually make a preliminary cut with cable cutters, and then trim off 6-7mm with the Dremel for a clean and straight cut.
Then while the plastic is still hot, i use a ballpoint pen to open up the melted inner liner. It works well because you can kind of mold it into a slightly wider opening, which makes threading cables into the housing easier.
For cutting cables themselves, you can use the cutting disc, but a real pair of cable cutters is far superior. I found the dremel tends to cause the individual strands of steel to kind of un-wind, which is a pain.