Working on fitting a vintage bike with some non-aero brake levers + vintage calipers. Calipers + levers are installed but I don't seem to be able to get the tension in the cable - it stays for a second but then the cable seems to "pop" at the lever end. I pulled the cable as tight as it will go through the caliper and fit the cable through the hole in the brake lever so the bigger side of the hole is facing the ground (smaller side of hole facing rider). I also have the housing on right now.

Any suggestions?

Those non-aero levers can be kind of a pain in that way. What I usually have to do is hold the lever in the closed position while I pull the cable tight enough to hold some tension on it, then pull it through the calipers and then get the cable as tight as I can. What's probably happening is that while you're routing the cable, you're not holding tension in the cable the whole time, and that allows the lever to sag a bit and the cable end to slip out of the hole.

get someone else to give you a second pair of hands, or hold the caliper closed with a heavy duty rubber band or strap, then your hands are free to tension the cable and tighten the nut. if it "pops" when you test the brake, you probably aren't tightening the clamp nut enough.

I have one of those "4th hand" tools as well as a cheap wire clamp (Bell, maybe) to hold brake pads closed. Both are helpful in doing brake work when there is no helper available.

thanks, I'll try that out!

"Third Hand Tools" are made to do just what your describe, hold the pads hard against the rim while the mechanic pulls on the cable and tightens the clamping bolt. A "Fourth Hand Tool" actually tensions the cable while the bolt is tightened.

Also, make sure you are using ferrules on the ends of the cable housing. Many older non-aero brake levers also require a 'beehive' style ferrule at the lever end thatkeeps the housing from popping into the lever base.

At the brake lever make sure that the end of the cable is well seated in the BIG hole end of the brake lever cable holder.

Cheers

A third hand. or a toe clip strap or a C clamp. Whatever you have around. Looks like Park Tool doesn't sell a third hand anymore. I put a dime or washer under each brake pad, before tightening up the cable. chris

Practice..