Go Back  Bike Forums > Bike Forums > Bicycle Mechanics
Reload this Page >

Heat Fusing Cable Ends?

Notices
Bicycle Mechanics Broken bottom bracket? Tacoed wheel? If you're having problems with your bicycle, or just need help fixing a flat, drop in here for the latest on bicycle mechanics & bicycle maintenance.

Heat Fusing Cable Ends?

Old 03-07-13, 11:52 AM
  #26  
nolken
Member
Thread Starter
 
Join Date: Aug 2012
Posts: 29
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Likes: 0
Liked 0 Times in 0 Posts
he said torch,so I'm assuming spot welding is out of the question.
nolken is offline  
Old 03-07-13, 11:56 AM
  #27  
Matariki
Not quite there yet
 
Matariki's Avatar
 
Join Date: Feb 2013
Location: Monkey Bottom, NC
Posts: 1,000

Bikes: A bunch of old steel bikes + an ICE trike

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 3 Post(s)
Likes: 0
Liked 2 Times in 2 Posts
Originally Posted by FBinNY View Post

On my own bikes I use a small oxy-acetylene torch with a reducing flame which rapidly heats and flame cuts the wire, leaving perfectly fused ends.
I used to do it this way - works like a charm. Of course you can't do it when the cable is already mounted. These days I use solder - it's easy on new cables but I have not had much luck on aged ones. You have to use a soldering iron. A torch overheats the cable and the resulting oxidation (even with flux) prevents the solder from flowing.
Matariki is offline  
Old 03-07-13, 01:02 PM
  #28  
chriskmurray
Senior Member
 
chriskmurray's Avatar
 
Join Date: Aug 2012
Location: Colorado Springs
Posts: 1,134

Bikes: Borealis Echo, Ground Up Designs Ti Cross bike, Xtracycle, GT mod trials bike, pixie race machine

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 8 Post(s)
Likes: 0
Liked 0 Times in 0 Posts
We cut them with a torch at our shop as well and it works great. You basically clamp the cable just behind where you want it cut in vicegrips, pull it taught and heat it with the torch (flame pointed AWAY from the bike/people obviously) and once it starts glowing you keep lightly pulling and twist quickly until it comes apart. It leaves an end that will simply not fray and can be removed easily. It also takes just a few more seconds than cutting it with cable cutters.
chriskmurray is offline  
Old 03-07-13, 03:11 PM
  #29  
ksisler
Senior Member
 
Join Date: Sep 2012
Posts: 1,732
Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 24 Post(s)
Liked 2 Times in 2 Posts
Originally Posted by fietsbob View Post
I solder the cable before final cutting , use a soldering iron, not open flame.
Ditto fietsbob, same here. I pull the cable to final length and cut it to that length with the Park tool, pull it out and flux and solder the end up (away from the bike). Then use a file flat file to round the edge just a bit. They it easily slides back in through the housing and fittings. /K
ksisler is offline  
Old 03-09-13, 06:55 AM
  #30  
Ol Danl
Full Member
 
Join Date: Dec 2004
Location: Chattanooga, Tn
Posts: 289

Bikes: 1977 Raleigh Record, 1987 Schwinn Prelude, 1971 Raleigh Record, 1988 Schwinn Traveler, 1967 (?) Carlton Super Course, 1959 Huffy Sportsman 3 speed, 1972 Raleigh Super Course, yet another 70-something Raleigh Record

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 40 Post(s)
Liked 5 Times in 5 Posts
Another source for crimps -- I've been using 3/32" o.d. brass tubing I got from ACE. Got 3 foot-long sticks for about $3, and cut off 1/2 inch pieces with a dremel.
Ol Danl is offline  
Old 03-09-13, 08:27 AM
  #31  
digger531
Senior Member
 
Join Date: Feb 2011
Location: St. Cloud, MN
Posts: 592

Bikes: Soma Double Cross DC, Salsa Vaya, Redline D440, '87 Schwinn Super Sport

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Likes: 0
Liked 0 Times in 0 Posts
Fabric paint works well and adds a touch of color. I am going to experiment with this "fusing" thing
digger531 is offline  
Old 03-10-13, 03:46 PM
  #32  
chucky
It's got electrolytes!
 
chucky's Avatar
 
Join Date: Aug 2009
Posts: 1,388

Bikes: Self-designed carbon fiber highracer, BikesDirect Kilo WT5, Pacific Cycles Carryme, Dahon Boardwalk with custom Sturmey Archer wheelset

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Likes: 0
Liked 0 Times in 0 Posts
Originally Posted by fietsbob View Post
I solder the cable before final cutting , use a soldering iron, not open flame.
+1 Just use a soldering iron to put a drop of solder on the end...available at any plumbling, hardware, or electronics store.
chucky is offline  
Old 03-10-13, 04:39 PM
  #33  
Airburst
Senior Member
 
Join Date: Oct 2009
Location: England, currently dividing my time between university in Guildford and home just outside Reading
Posts: 1,921

Bikes: Too many to list here!

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
Likes: 0
Liked 4 Times in 2 Posts
Originally Posted by chucky View Post
+1 Just use a soldering iron to put a drop of solder on the end...available at any plumbling, hardware, or electronics store.
Soldering to modern stainless steel cables tends to be the difficult bit. Electronics solder doesn't have the right flux in it for stainless, I can't vouch for plumbing solder as I've never really used it.
Airburst is offline  
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
Mechanicjay
Classic & Vintage
8
09-07-19 04:36 PM
Monkey Face
Bicycle Mechanics
16
09-23-16 03:33 PM
speedevil
Bicycle Mechanics
26
07-31-13 08:28 AM
TromboneAl
Bicycle Mechanics
25
03-21-11 02:34 AM
BluesDaddy
Classic & Vintage
47
12-26-09 05:40 PM

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off


Thread Tools
Search this Thread

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service - Do Not Sell or Share My Personal Information -

Copyright © 2023 MH Sub I, LLC dba Internet Brands. All rights reserved. Use of this site indicates your consent to the Terms of Use.