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Old 03-23-13 | 08:43 AM
  #21  
coreseller
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Joined: Mar 2013
Posts: 11
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I'll go ahead and respond so this could be used as a reference in case someone else wants to fabricate their own longer cable. I will list the steps I took:

-Buy 1/16 cable from Lowes or Home Depot, both sell it.

-Cut an existing cable end (Road or Mountain Style) that's in good useable condition off of cable.

-Drill out the center of the cable end to create the hole needed for new cable and eliminate the existing cable / wire from it.



-Push the new cable through the hole (you need a clean cut, easily achieved with a dremel), splay / fray the end of of the cable after through and clean it off with MEK or another type of solvent cleaner. Thoroughly dry the end of the cable with a clean towel, you don't want any solvent left on it.



-Take measurements of the cable end to refer to when you "reshape" it after soldering. Push frayed end of cable into flux working it into the cable and down into the hole. Be liberal with it.



-Use a soldering pot or make your own (I used a 1/2" copper cap) heat it up with a torch, put 60-40 (solid, you cannot use acid or rosin core) solder into pot, wait for it to melt and flow. Carefully dip cable end on molten solder and hold it there for 20 to 30 seconds>



-A video I watched to use as a guide to making the solder pot:


-Remove cable from solder pot and let everything cool down for 10 to 15 minutes.



-use a grinding wheel / file / dremel to reshape the end referring to prior measurements taken. I pulled on this as hard as I could, I'm convinced it's every bit as if not stronger than a factory applied end.



-Go to you local bike shop and purchase the cable covering (by the foot) and end caps / ferrules.

Thanks again for the help guys......Mark.
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cable6_zps8937ecb2.jpg (27.7 KB, 63 views)

Last edited by coreseller; 03-23-13 at 08:53 AM.
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