Mountain Biking - DIY Full Metal Jacket Brake Cables

So I was inspired. Only the cost drove me away. Sooo, I made my own.

Don't mind the dates..

Supplies:
http://i75.photobucket.com/albums/i317/xboxpix/DCP_0010-1.jpg

Use your dremel and cut your stainless pipe to the proper length, wrap some electrical tape around the end and slide it in:
http://i75.photobucket.com/albums/i317/xboxpix/DCP_0005.jpg

Put the epoxy around the edge and let it dry. Super glue might also work, but I never have any luck with it:
http://i75.photobucket.com/albums/i317/xboxpix/DCP_0006.jpg

Neatly wrap some more electrical tape around the join, making it as tight as possible:
http://i75.photobucket.com/albums/i317/xboxpix/DCP_0007.jpg

Fit on your mounting piece. Mine came off the fork with a small allen wrench screw:
http://i75.photobucket.com/albums/i317/xboxpix/DCP_0008.jpg

Run your wire through the cable and fit it on your brakes:
http://i75.photobucket.com/albums/i317/xboxpix/DCP_0009.jpg

Adjust everything and your good to go:
http://i75.photobucket.com/albums/i317/xboxpix/DCP_0011.jpg


I was utterly amazed at how responsive this is. I Shortened the cable so there isn't so much bend, and it is just insane. I like this better than any other cable I have ever had. My friend has the gore ride ons, full enclosed, and this is more responsive than his 50 dollar cable. So for a 2 dollar cable and a 3 dollar pipe, you can have an insanely responsive front brake system :)

Can we have the specs of the pipe?

Also, when you say "Use your dremel and cut your stainless pipe to the proper length, wrap some electrical tape around the end and slide it in:" you're putting electrical tape around what, and putting it in where?

Very cool idea. Where did you score the pipe? An industrial supply place like McMaster Carr or MSC?

i don't know what to say? have you ever tried hydraulic line instead?


:D jk. good job

mx

Very cool idea. Where did you score the pipe? An industrial supply place like McMaster Carr or MSC?

i've seen stuff like that at ACE or hobby stores

Can we have the specs of the pipe?
I will get the specs on the pipe later and I will edit it into my original post. My father got it for me from this catalog at his work.

Also, when you say "Use your dremel and cut your stainless pipe to the proper length, wrap some electrical tape around the end and slide it in:" you're putting electrical tape around what, and putting it in where?

You are putting electrical tape around the joint where the cable goes inside of the pipe.
1.) Because it makes it even more water proof
2.) It looks better than some blobbed up epoxy around the pipe
3.) It is more secure and doesn't budge when it is snapped inside the plastic holding piece.

You are putting it in a cable guide somewhere near the top of your fork. Your fork might already have a metal one, It might have a removable plastic one like mine did, or it just might not have one at all.
This is a zip tie type (http://www.pricepoint.com/detail/15787-050_ALIG26-3-Parts-49-Cables/Alligator-The-Gripper-2-Zip-Tie-Hydraulic-Hose-Guide.htm)

Mine is simply that, but it was screw on.

You are putting electrical tape around the joint where the cable goes inside of the pipe.
1.) Because it makes it even more water proof
2.) It looks better than some blobbed up epoxy around the pipe
3.) It is more secure and doesn't budge when it is snapped inside the plastic holding piece.



Heat shrink would look and work better than electrical tape.

Heat shrink would look and work better than electrical tape.

I suppose this is true. I didn't even think of that. The only kind I have that size is blue though:(

Heat shrink or silicone vulcanizing tape (Nashua Stretch-N-Seal tape @ Home Depot) would work great.

I just used what I had on hand. Theres not a huge need for anything considering the epoxy is waterproof.

I used heat shrink when I was running Avid mechanicals/FMJ housing. Worked very well to seal things up. Good job on the home brew setup.