These: https://www.jensonusa.com/MTB-Brake-Cables

versus these: https://www.jensonusa.com/Jagwire-Slick-Brake-Wire

The Jagwire cables claim to be die-extruded. Are the other cables made differently somehow? I'm particularly curious about this, and am wondering if all cables are die-extruded whether their descriptions claim so or not.

Extruded wire? I thought wire was drawn.

Anyway, I'd disregard anything relating to strength; it's not a consideration. Friction is where it's at...

Actually, looking at this:



It looks like you could call that extruding.

https://en.wikipedia.org/wiki/Wire_drawing

Actually, not really. At least, not correctly.

Extrusion appears to be a totally distinct process, with no tension.

https://en.wikipedia.org/wiki/Extrusion

I don't think that would make good wire; I'm guessing it's incorrect usage of the term.

I guess my question is, is the less expensive brake cable undrawn? I have tried in the past to see and feel a difference between Jenson's generic and the Jagwire cables. If there is a difference, I cannot discern it.

You probably would if you looked closely at the cables in person. The better quality cables are pulled through a die which makes the outside diameter of the cable smooth so it will slide theough the cable housing more easily.

I have actually, in the past, ordered both cables and looked at them in person. However, it's possible I don't now what to look for. It's possible my hands just don't feel it. I ordered a couple of each this time, so that I can compare once again.

Maybe the cheaper ones are also die drawn, and the marketing copy just doesn't mention it.

die drawn cables flatten the outer surface , of the finished cable,
so move more easily within the Housing.

makes your Index stuff click better. in both directions ..

and the brake cable pull feels smoother ..


look at flatwound guitar strings. in comparison the player
does not get the zipping noise moving their fingers up/down them,
like they do with round wound..

I didn't know there was such a thing, that sounds great.

I wouldn't call it extrusion, and in the past JagWire called it "die drawn", but maybe they were looking for a more technical sounding word for marketing.

Anyway, here's what it's all about. Brake and gear cable inner wires are made of multiple strands wound together in a number of patterns. The simplest is 6 wires spiraled around one (get 7 pennies and follow along) and described as 1x7 (1 bundle of 7 strands). The next step is to wind 12 strands around the original 7 but in the opposite direction, called 1x19. You can continue building up the cable adding layer upon layer until you give up.

The other alternative is to do the same process, but using bundles in lieu of wires, making a cable of 7 bundles of 7 strands each, 7x7, or 7x19, or 19x19 and so on. These are often called braided cables in the bike world because they look that way, out of the bike world they're usually called wire rope.

Regardless of how cables are made the surface is rougher than a single wire strand would be (see your 7 pennies). This surface roughness which we lived with for almost a century became a problem when we went to lined housings, because they'd cut through the liner pretty quickly. So makers like JagWire take the wire and draw it through a die or between shaped rollers, to squash that uneven surface smooth. (picture squashing the outer pennies into pie wedges)

Die drawn wires are pretty important for gear wires because they run smoother and so make for better indexing with the lightly sprung RDs.

But there's a drawback (no pun) to die-drawn wires. The process makes the cable less supple, and more prone to metal fatigue where it flexes over pulleys

So that;s what it's about, and not all wires are die drawn. But that's one consideration when buying cables, along with whether they're made of stainless steel, or coated for lower friction.