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Well, i made a tool tonight to make new cable ends for broken clutch/brake cables. All you need a a small chunk of wood (probably about 3 inches wide and about 3 inches long). Take a drill or drill press and a bit the same side as the end that came off and drill a hole in the wood that doesnt go all the way through. Then take a dremel tool and cut a notch in the wood from the hole to one edge thats about midway down the hold you just drilled. Make sure the hold is as deep as the end that came off too (or deeper). You will need a file or bench grinder to do this as its very unlikely to come out with an end thats the exact size you need. once you have the tool made, melt down some 60-40 tin/lead solder into the hole until its full and shape the new end until it fits into your lever. I actually have a smelter thats made for melting lead so i just melted down some fishing weights to use as my new end. I just got done putting on the new cable, installing it, and yanking on the lever a whole bunch and it seems to be holding about perfect. If you have a way to smelt aluminum theres no way this shouldn't work. Try it you guys, it will save you the time of waiting for a new cable and some money that would be great for gas, cigarettes, or beer

Just remember the grease for those ends so they dont stick and cause pre-mature wire wear.

Yep, i used silicone lubricant just so i could jump on my bike to go for a quick spin with my dad. The cable worked out great. Hasn't failed on me yet and if it does, ill just take the mold i made and put another end on it until i get one that lasts me a good long while. Not thinking its gonna break again though.

Kitten Tooth wrote: Well, i made a tool tonight to make new cable ends for broken clutch/brake cables. All you need a a small chunk of wood (probably about 3 inches wide and about 3 inches long). Take a drill or drill press and a bit the same side as the end that came off and drill a hole in the wood that doesnt go all the way through. Then take a dremel tool and cut a notch in the wood from the hole to one edge thats about midway down the hold you just drilled. Make sure the hold is as deep as the end that came off too (or deeper). You will need a file or bench grinder to do this as its very unlikely to come out with an end thats the exact size you need. once you have the tool made, melt down some 60-40 tin/lead solder into the hole until its full and shape the new end until it fits into your lever. I actually have a smelter thats made for melting lead so i just melted down some fishing weights to use as my new end. I just got done putting on the new cable, installing it, and yanking on the lever a whole bunch and it seems to be holding about perfect. If you have a way to smelt aluminum theres no way this shouldn't work. Try it you guys, it will save you the time of waiting for a new cable and some money that would be great for gas, cigarettes, or beer

Hi KT,

Glad that worked for you. But the solder/lead ends will wear quickly. A better fix would be to pick up a piece of brass bar from the hardware store that's of the proper diameter. Drill a hole through it to fit the cable then drill a larger hole half way through following the first hole. Now cut the bar to length stick the cable through the hole, open the wires slightly, pull the cable back into the bar and solder the wire in.

Just a suggestion

Bill

Heres a link on how to make cables.www.chopcult.com/forum/showthread.php?t=166

you can also get cable parts at flanderscompany.com Pretty reasonable prices and they are super nice and easy to work with. You can get all the cable ends, conduit, etc that you need if you don't want to make your own