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Internal cable routing through aero handlebars

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Internal cable routing through aero handlebars

Old 01-13-19, 02:09 PM
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Brad Bike
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Internal cable routing through aero handlebars

I'm trying to install new brake and shifter cable housings for the first time, but I have Zipp aero handlebars that route everything internally. I'm pushing the housings through the outside holes (closer to the shifters), but I'm having trouble getting them to come out the other hole (closer to the stem). Any tips/tricks for getting them through?

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Old 01-13-19, 02:11 PM
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tyrion
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Use a vacuum cleaner to pull a thread through the route, then use the thread to pull the thread to pull the cable.

(I haven't done it, saw it on a video.)
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Old 01-13-19, 03:26 PM
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maybe put the cable in (new ones with melt cut ends wont fray) then put the housing in there over the cable..

even if the cable goes in backwards to get it to work, once the housing is in, you can pull the cable , turn it around and put it back thru the housing..
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Old 01-13-19, 06:54 PM
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So will the bars spontaneously combust if you routed the casing outside the bars?? Andy
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Old 01-13-19, 07:51 PM
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Originally Posted by Andrew R Stewart View Post
So will the bars spontaneously combust if you routed the casing outside the bars?? Andy
Lol, no but they are swanky swanky Zipps so I'd like to avoid taping over the branding if I can (I bought this bike used, so I'm trying to maintain the look that came with it... It's pretty cool)
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Old 01-13-19, 07:54 PM
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...I just did a bunch of internal cable routing to repaint and reassemble a Casati frame.

You hear a lot of stuff on the internet that has never worked for me in doing internal brake cable routing. The most effective way for me to do this (and what I did on my Casati) is to get a long piece of single stranded wire that is stiff enough to run from pushing on the rear, but easily bent so you can fish it from the other side.

Run your wire backwards from the direction you want the cable to eventually pull through. either measure before you insert it about where the exit hole is and mark it on the wire, or if it's heading toward a dead end anyway, use that as your guide. Twis up a short piece of the same wire, with a small hook on one end (needs to fit through the hole) and a loop on the other end you can hold it and turn it with,

Then insert your hook into the exit hole and fish out the wire at that end. Attach the cable end of the cable you want to pull to the end of your wire with a length of small diameter heatshrink. Use the wire to pull the cable. But honestly speaking, I'm with Andy on this. I've never yielded to the compulsion to run brake cables inside the bar. I only did it inside the top tune on this Casati because the fittings were already brazed into the frame, and the derailleur cables run internally too.
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Old 01-13-19, 08:43 PM
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It's really not that difficult once you do it a few times. I like to cut my housings a little longer than I think I'll need to start (you can cut them to the correct length after everything is routed). I'll slide some old inner wires into the housings as a guide, and pull the inner cable all the way through until the cable head bottoms out on the end of the housing. Take the other end of the excess inner cable and work it through the bars. A magnet will help if your having trouble getting it through. Once you get it through the exit hole, pull the housing on through.
I made a video with some internal cable routing tips a year or so ago. The video shows a handlebar routing example about the 5:00 point in the video.

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Old 01-14-19, 03:15 PM
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Thanks for all the great advice, guys. I'm going to try running a piece of wire through first to see if that will work I really appreciate everyone's help!
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Old 01-14-19, 06:18 PM
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Originally Posted by Brad Bike View Post
Lol, no but they are swanky swanky Zipps so I'd like to avoid taping over the branding if I can (I bought this bike used, so I'm trying to maintain the look that came with it... It's pretty cool)
Just get a helmet, jersey and shorts with the brand name printed in huge letters all over them. Problem solved!

(Plan B is the legally change your name to said brand, and this way nobody will ever forget)
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