extending a shift cable
#1
Thread Starter
Senior Member
Joined: Jun 2009
Posts: 819
Likes: 56
extending a shift cable
Like the title says, the shift cable some some routing through the bike frame so I don't want to remove it. I think to remove it would also require me to remove the mid drive motor.
What's the best way to extend or add on to it? I'm thinking just cut a piece of shift cable and use electrical shrink wrap to hold it.
What's the best way to extend or add on to it? I'm thinking just cut a piece of shift cable and use electrical shrink wrap to hold it.
#2
Senior Member




Joined: Sep 2017
Posts: 10,300
Likes: 14,750
Like the title says, the shift cable some some routing through the bike frame so I don't want to remove it. I think to remove it would also require me to remove the mid drive motor.
What's the best way to extend or add on to it? I'm thinking just cut a piece of shift cable and use electrical shrink wrap to hold it.
What's the best way to extend or add on to it? I'm thinking just cut a piece of shift cable and use electrical shrink wrap to hold it.
__________________
#3
Senior Member


Joined: Aug 2015
Posts: 814
Likes: 663
From: Delaware Sea Shore
Bikes: There is always room for one more.
Cable splitters for S&S Coupled travel bikes
You can probably find other options as well with a two minute Google (or your favorite search engine) search.
__________________
Don
Don
#4
Senior Member


Joined: May 2010
Posts: 5,603
Likes: 2,468
From: Bastrop Texas
Bikes: Univega, Peu P6, Peu PR-10, Ted Williams, Peu UO-8, Peu UO-18 Mixte, Peu Dolomites
I have never had great success splicing a bicycle cable to lengthen it. I have tried though. It always looked super BAD. Just get yourself another cable...
Youtube: Incredible Huge Rope Splicing & Fabricating Process - Amazing Factory Machines Production Technology
Youtube: Incredible Huge Rope Splicing & Fabricating Process - Amazing Factory Machines Production Technology
__________________
No matter where you're at... There you are... Δf:=f(1/2)-f(-1/2)
#5
Senior Member
Joined: Mar 2013
Posts: 545
Likes: 501
From: Albany, NY
Bikes: Trek FX 7.3, Orbea Terra, Aostimotor S17 ebike, Huffy RedRock (first bike)
some internal cables are easier to route than you think, just make sure your string is good quality and securely attached to the cable you're removing.
#8
One tip I discovered here on BF is to use the old cable as a fish wire, cutting any ends off the old cable and connecting the old and new cable with a length of thin (such as 1/16" I.D.) shrink tube long enough for good grip as it's pulled through. Worked great for me on my most recent attempt.
__________________
Richard C. Moeur, PE - Phoenix AZ, USA
https://www.richardcmoeur.com/bikestuf.html
Richard C. Moeur, PE - Phoenix AZ, USA
https://www.richardcmoeur.com/bikestuf.html
#10
Senior Member


Joined: Mar 2016
Posts: 3,678
Likes: 2,053
From: Sussex County, Delaware
You can get housing end caps that are one unit, but open at both ends with a separator in the middle of the cap, ergo, you need two pieces of housing of the correct lengths. Or, you can use two housing end caps with the closed end back to back, and the same with two pieces of housing. The cable runs straight through either option. With the back to back caps, you could wrap them with tape of the same color, but it is not necessary. Either way, can be seen only from close up. They work just like the cable stops on the frame.
Using just tape to splice the housing together will work, but not work that well. the connection just is not stiff/strong enough, IME.
Using just tape to splice the housing together will work, but not work that well. the connection just is not stiff/strong enough, IME.
Last edited by delbiker1; 10-25-23 at 05:54 PM.
#11
Senior Member

Joined: Feb 2006
Posts: 2,945
Likes: 255
From: Sin City, Nevada
Bikes: Catrike 700, Greenspeed GTO trike, , Linear LWB recumbent, Haluzak Horizon SWB recumbent, Balance 450 MTB, Cannondale SM800 Beast of the East
If you are not fussy and want to use one of the more expensive housing brands like Jagwire or Shimano, standard cable housing is pretty inexpensive bought online. I'm still working with a 25 foot roll of shifter cable purchased from Nashbar more than a decade ago. This happens to be a source located one town away who sells on eBay.
12 foot roll of 5mm shift cable $16 postpaid https://www.ebay.com/itm/291917358195 same company 25 foot roll $25 postpaid https://www.ebay.com/itm/391259402350
12 foot roll of 5mm shift cable $16 postpaid https://www.ebay.com/itm/291917358195 same company 25 foot roll $25 postpaid https://www.ebay.com/itm/391259402350
#12
Junior Member

Joined: Feb 2006
Posts: 191
Likes: 77
Sheldon Brown (or John Allen) says splicing a cable is easy and does not require any extra hardware:
https://www.sheldonbrown.com/heroic-repairs.html
scroll down to the "splicing cables" section
https://www.sheldonbrown.com/heroic-repairs.html
scroll down to the "splicing cables" section
#13
I've used shrink tubing for this purpose (over the back to back ferrules) with good results.
__________________
Richard C. Moeur, PE - Phoenix AZ, USA
https://www.richardcmoeur.com/bikestuf.html
Richard C. Moeur, PE - Phoenix AZ, USA
https://www.richardcmoeur.com/bikestuf.html
#15
Senior Member


Joined: Aug 2009
Posts: 3,130
Likes: 1,632
I have a bike with a thru-frame rear brake cable routing. Nearly the entire length of housing goes through the top tube. The way I replace the housing is to leave a headless brake cable in there all the way through while pulling out the housing. Then reverse the process to install new housing. I keep the headless cable in my tool box just for this operation.
#16
Senior Member
Joined: Mar 2021
Posts: 2,090
Likes: 513
Do you have a little metal (pref aluminum) cylinder? Could drill and tap a hole on either end of it and use socket head set screws to grab the cable. 4-40 screw should be plenty strong. Simple, strong, and elegant, but you’d need the tools
A quicker way could be just tie a knot. I doubt it would work but you could try, it’s probably what I would do just to see if it works.
I agree rerouting it seems like a *****
another option could be to get a nice zip tie, and use a lighter and a needle to poke two holes through it, tie the zip tie to itself. Thread the housing through the melted holes and then figure out how to make the end bunched up so it can’t fit back through the melted hole in the zip tie. One looped knot and some glue so the loop doesn’t slip out should work fine. The zip tie is acting like a shackle, it would probably hold honestly.
A quicker way could be just tie a knot. I doubt it would work but you could try, it’s probably what I would do just to see if it works.
I agree rerouting it seems like a *****
another option could be to get a nice zip tie, and use a lighter and a needle to poke two holes through it, tie the zip tie to itself. Thread the housing through the melted holes and then figure out how to make the end bunched up so it can’t fit back through the melted hole in the zip tie. One looped knot and some glue so the loop doesn’t slip out should work fine. The zip tie is acting like a shackle, it would probably hold honestly.
Last edited by LarrySellerz; 10-26-23 at 07:46 PM.
#17
Senior Member
Joined: Mar 2021
Posts: 2,090
Likes: 513
Sheldon Brown (or John Allen) says splicing a cable is easy and does not require any extra hardware:
https://www.sheldonbrown.com/heroic-repairs.html
scroll down to the "splicing cables" section
https://www.sheldonbrown.com/heroic-repairs.html
scroll down to the "splicing cables" section
#18
Senior Member


Joined: Jul 2005
Posts: 6,916
Likes: 1,260
Good Lord, 20 posts. My newest bike has internally routed cable but I haven't had to replace it. I didn't realize it was this hard. Maybe it is, maybe it isn't, but I have to think Park Tool or Sheldon Brown or some other technical authority has a best practice tutorial in one of the usual places. If I had to do it myself I would already be on it. Let's get this thread notched up to #useful status and find a peer reviewed authority to post a link from.
Edit: A start? <shrug>
Edit: A start? <shrug>
Last edited by Leisesturm; 10-26-23 at 09:29 PM.
#20
Senior Member


Joined: Mar 2016
Posts: 3,678
Likes: 2,053
From: Sussex County, Delaware
I have replaced internally routed cables/housing once on my Orbea Avant. I bought the Shimano routing tool, but, after doing the work, I realized I could have done it without the tool with no more time and hassle involved. I dreaded doing it the first time, but I am pretty sure if/when I do it again, it will go a lot quicker. I believe different manufactures use different techniques in the routing, ergo, there will be some differences in the replacement process. It seems likely to me that frame sets with oversized tubing make it a bit easier.
#21
Senior Member



Joined: Oct 2008
Posts: 3,033
Likes: 795
From: in a house
Bikes: Specialized Aethos, Specialized Diverge Comp E5 and 2025 Spesh Tarmac SL8 Expert
I use the cable as a guide, sliding the housing out of the frame leaving the shift/brake cable intact then sliding the new housing up the cable. I don't worry about the length at that moment, only that it extends beyond both ends of the frame, then I remove the cable and size the housing cutting it to the correct length. I then install a new cable and voila I'm done.
#22
Senior Member


Joined: Aug 2009
Posts: 3,130
Likes: 1,632
I use the cable as a guide, sliding the housing out of the frame leaving the shift/brake cable intact then sliding the new housing up the cable. I don't worry about the length at that moment, only that it extends beyond both ends of the frame, then I remove the cable and size the housing cutting it to the correct length. I then install a new cable and voila I'm done.
#23
Advanced Slacker

Joined: Feb 2017
Posts: 6,286
Likes: 2,602
Bikes: Soma Fog Cutter, Surly Wednesday, Canfielld Tilt
https:/jagwire.com/products/small-parts/connecting-junction-ferrules
Don’t even need to tape it if you don’t want to. Had one of these on hand when running the cables for my commuter. I did not have any housing runs long enough for what I needed and this worked great.
Last edited by Kapusta; 10-27-23 at 07:30 PM.
#24
Method to My Madness

Joined: Nov 2020
Posts: 4,727
Likes: 2,065
From: Orange County, California
Bikes: Trek FX 2, Cannondale Synapse x2, Cannondale CAAD4, Santa Cruz Stigmata 3
I would use one of these:
https:/jagwire.com/products/small-parts/connecting-junction-ferrules
Don’t even need to tape it if you don’t want to. Had one of these on hand when running the cables for my commuter. I did not have any housing runs long enough for what I needed and this worked great.
https:/jagwire.com/products/small-parts/connecting-junction-ferrules
Don’t even need to tape it if you don’t want to. Had one of these on hand when running the cables for my commuter. I did not have any housing runs long enough for what I needed and this worked great.




