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Handlebars with Internal Cabling

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Old 03-17-08 | 01:43 PM
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Handlebars with Internal Cabling

Anyone know of a reasonably easy technique to route brake housing through handlebars? I assume the basic idea is to get the cable through first and then slip the housing over it. But I'm finding that's easier said than done. Then again, maybe that's the wrong approach? The handlebars in question are mid-80's 3ttt aero handlebars.
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Old 03-17-08 | 01:58 PM
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It takes patience indeed
I find that if you put a slight bend in the cable - not a sharp kink of course, but a subtle arc, it definitely helps in trying to find the "exit" hole. Yes, you are correct in the way you are going about it - cable first, then slide the housing over.
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Old 03-17-08 | 02:10 PM
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Originally Posted by Antipodes
It takes patience indeed
I find that if you put a slight bend in the cable - not a sharp kink of course, but a subtle arc, it definitely helps in trying to find the "exit" hole. Yes, you are correct in the way you are going about it - cable first, then slide the housing over.
Okay, thanks very much. I'll have to be more patient. Part of me wonders if bike companies that had to assemble these in any great numbers had either a trick or a special tool they used to speed things up. It is pretty tedious work.
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Old 03-17-08 | 06:52 PM
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Place big magnet near the hole to guide the inner wire then slide the housing over it.......

Next time around side the old housing off.....insert new housing wire. Remove old inner wire...insert new inner wire
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Old 03-17-08 | 06:58 PM
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Originally Posted by miamijim
Place big magnet near the hole to guide the inner wire then slide the housing over it.......

Next time around side the old housing off.....insert new housing wire. Remove old inner wire...insert new inner wire
I'm not sure at the moment if I have a magnet like that, but your advice sounds reasonable. Much obliged!
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Old 03-17-08 | 07:04 PM
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Originally Posted by gridplan
I'm not sure at the moment if I have a magnet like that, but your advice sounds reasonable. Much obliged!
I was exaggerating...when I feed the shifter cables through the downtube of my Klein I used a big refridgerator magnet.
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Old 03-17-08 | 08:35 PM
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Bikes: Crap. The box is not big enough...

oh, yeah. The absolute worst internal routing problem eva! Kleins are the top.
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Old 03-18-08 | 03:10 AM
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Use a piece of coat hanger (or other stiff wire) first. You can bend it however you need to to make it go through. Then tape the end of the cable to the stiff wire & pull it through.

I have never tried the magnet trick, but it sounds useful!
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Old 03-18-08 | 05:25 AM
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If you dont't want to waste hours use a vacuum cleaner and a string first to pull the inner cable through the holes.
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Old 03-18-08 | 09:54 AM
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There was a post about this very recently with some good tips, if I recall correctly.
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Old 03-18-08 | 04:48 PM
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Air compressor. plug all the holes except 2. blow in one and push your cable through the other with the air.
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Old 03-18-08 | 07:49 PM
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I won't be able to revisit this until the weekend. But I will try out one or more of these techniques until both cables are routed. Thanks to all who responded!
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