Cable cutting and attention to detail
12-13-09, 09:45 PM
#28
All-round nice guy.
Join Date: May 2005
Location: Ontario Canada
Posts: 448
Bikes: Kish road bike, Seven mtb, Marinoni road and track bikes.
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This is what I do for casing -
1. Cut to length with cable cutters (which leaves a crappy end).
2. Grind casing square on small grinder.
3. While everything is very hot and the plastic liner is soft I push a spare cutoff piece of inner wire down the casing section 'till it comes out the newly cut end (thus widening out the melted liner).
4. Wiggle the wire around to widen the hole more.
5. Announce "Ta-daaaaaa".
1. Cut to length with cable cutters (which leaves a crappy end).
2. Grind casing square on small grinder.
3. While everything is very hot and the plastic liner is soft I push a spare cutoff piece of inner wire down the casing section 'till it comes out the newly cut end (thus widening out the melted liner).
4. Wiggle the wire around to widen the hole more.
5. Announce "Ta-daaaaaa".
12-13-09, 10:36 PM
#29
Bicycle Repair Man !!!
Your reply lacks some attention to detail... 
But I know can always try being clearer... compression is probably not an accurate term for what happens where a cable end meets a ferule as it is more a case of that unfinished end crushing and conforming itself to the inside of the ferule over repeated cycles of higher and lower cable tension.. the more that end has to deform to fit the greater the change in cable tension.
The ferule also has to seat itself into the frame but as this is usually steel against steel or aluminium it happens fairly quickly.
Over a run of cable there are many points where this can happen and when you add it up you can end up getting some degradation in performance as the effective cable length becomes shorter as the housing gets shorter.
This is most noticeable on indexed shifting systems.
Facing off and finishing those cable ends allows for quicker and smoother seating as if the cable ends fit the ferule from the start they can be set after a few cycles of shifting / braking... by taking a little extra time during the set up one can all but eliminate the need for that "break in" adjustment or at the very least, it will be minimal.
But I know can always try being clearer... compression is probably not an accurate term for what happens where a cable end meets a ferule as it is more a case of that unfinished end crushing and conforming itself to the inside of the ferule over repeated cycles of higher and lower cable tension.. the more that end has to deform to fit the greater the change in cable tension.
The ferule also has to seat itself into the frame but as this is usually steel against steel or aluminium it happens fairly quickly.
Over a run of cable there are many points where this can happen and when you add it up you can end up getting some degradation in performance as the effective cable length becomes shorter as the housing gets shorter.
This is most noticeable on indexed shifting systems.
Facing off and finishing those cable ends allows for quicker and smoother seating as if the cable ends fit the ferule from the start they can be set after a few cycles of shifting / braking... by taking a little extra time during the set up one can all but eliminate the need for that "break in" adjustment or at the very least, it will be minimal.
