Do they make ferrules for 4mm and 5mm shift & brake housings that still fit into the braze-on cable guides on my Schwinn Super Sport?

I was using a 4mm shift housing without a ferrule on a Shimano bar end shifter until it quickly became mangled in the shifter housing stop during testing,

so I put on the housing that came with the shifter kit (I assume also 4mm), which has a plastic ferrule on the tip, and it fit nicely into the bar end shifter stop ...

but I had to cut off the other end because the ferrule didn't fit into my braze-on cable guide.

Any idea why my shift housing mangled in the shifter stop? I imagine not having a ferrule on it played a part?

I'm not sure if the mangling is only likely at cable stop points ... but thought it might be nice to have ferrules in the guides too.

The cable was Sunlite 4mm SIS cable. The plastic outer housing rode up the wire mesh, in the stop, and the mesh wires mangled each other and prevented the shift lever from moving properly.

Thanks,
sm

Index housing having a shallow spiral and the wire ends burring up against a stop require a flat bottom ferrule, or other flat stop. Otherwise, the conical bottom of most ferules, and fittings causes the wires to squeeze together and try to extrude though the hole.

While you see a plastic ferrule, which wouldn't address this, you don't see a steel plate at the bottom which take the load from the wires, an is usually made with a reverse cone (imagine a volcano shape) which drive the wires out and away from the hole.

Depending on the details, you might get by using a simple washer with a hole only big enough for the wire. Or they do offer the right type of ferrule for sale, but that depends on the ID of the stops.

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One simple thing which can help the mangling problem is to always touch the blunt end of the cable casing to a grinding wheel to get the blunt end to present a flat surface against wherever it seats.

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Older Schwinns were made for small diameter spiral wound (like current brake) casings. There are step down casing end caps for 5mm SIS casing available. Most better shops don't toss out the spares and optional bits that come with cable sets and such. I suspect that one of these step down casing caps will fit the frame stops. Andy

Shimano makes a step-down ferrule that might work.
https://www.universalcycles.com/shop...&category=1613

It may be a 4 to 5 mm step down ferrule is all you need. They are a common part. Shouldn't be any trouble to find them.

Thanks all for the info and suggestions ... I will see if I can get some step down ferrules.