Author Topic: How to shorten control cables? Anyone done it?  (Read 2491 times)

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Offline manjisann

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How to shorten control cables? Anyone done it?
« on: October 13, 2009, 10:44:04 AM »
I mated some 750 carbs to my 650 and the pull cable on the carb is about an inch to long, even if I try to adjust the cable out. Has anyone done a custom shortening job? I was thinking I could cut the barrel end off, drill out the old cable bit, cut the cable to the length I want, and then use some electrical solder to "weld" it back together, would that work?? Since I haven't even had the bike running I'm trying to avoid getting a "custom" cable made.

Thanks,

Brandon
Sure it's for sale! How much you ask?? Well, how much are you willing to pay??? Now triple it, that's the price!

1973 CB500 K2 - Sold the bike and bought a Mig, Miss the bike, Love the Mig :D
1980 CB650 Custom
1971 CB500 Frame 650 engine: Project

Trip and General Ramblings blog: manjisann.blogspot.com

Offline w1sa

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Re: How to shorten control cables? Anyone done it?
« Reply #1 on: October 14, 2009, 04:33:58 AM »
You can get new barrels etc.
Soldered ends usually incorporate a splay in the cable's end to assist the 'hold' or 'grip' of the barrel. The splayed end sits in the most open side of the barrel and is buried in the solder fill. If you try reusing the old end piece you should probably copy this method.

Perhaps the old cable end/barrel  might be removed by desoldering (either before or after cutting the cable) and then cleaned and reused
If using a torch, be careful not to over expose the cable to excessive heat.

It will work, but preferably practice on some other (same size) cable and test, before attacking your good cable.

If it seems too risky, an auto cable maker would probably shorten the cable end and fit a new barrel,  at reasonable cost...........:)

Offline Bodi

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Re: How to shorten control cables? Anyone done it?
« Reply #2 on: October 14, 2009, 06:51:19 AM »
It's possible to shorten cables, but not easy. The solder used isn't normal electrical stuff, that's too soft to hold much pull. Maybe for a throttle cable, but definitely no good for a brake or clutch cable. At the OEM factory (I watched at a small cable works in Osaka) they slip the nub on, crush the wire end with pliers to open the cable strands a bit, slide the nub down in place, then dip just the tip in hot liquid flux and then a very hot solder pot. I don't know what the metal mix they use is, but it is very hot - not as hot as you would need for silver solder but hotter than the 600F or so needed for electrical solder.
The only stuff I have found for this job is brazing rod or silver solder (probably no actual silver in it): both are harder and melt at a much higher temperature (dull red glow) than electrical or the mystery OEM solder, beyond the range of a soldering iron or propane torch. You need a gas + oxygen torch, a proper oxy-acetylene rig is good or you can get a home kit with small cans of some gas (not acetylene) and oxygen that works pretty good.
One problem is the old cable wire being soaked in lube and probably rusting a bit over the years. That makes it rather difficult to get clean enough to "tin up" with solder. Using an aggressive flux and lots of heat will usually work, but using a new core wire is the best bet. One tends to either overheat and weaken the core, or wick solder way up stiffening the cord for the end inch where it really needs to be flexible.
You can buy the inner core wire and the various end nubs (and the outer tube and sleeves too), if you have the torch and stuff to do silver soldering then making your own cables is easy. The only trick is to avoid having the solder wick up and stiffen the end, that's a matter of controlling the heat so only the nub and last few mm of cable core get hot enough to melt the solder.

Offline 754

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Re: How to shorten control cables? Anyone done it?
« Reply #3 on: October 14, 2009, 07:56:44 AM »
Use very sharp nips, and make sure you have a ferrule end on the cable if it used one.. and the correct solder..

 If it is the sharply bent down return cable make sure it has a good fit on the end.. (mine is hanging up because it does not)
Maker of the WELDLESS 750 Frame Kit
dodogas99@gmail.com
Kelowna B.C.       Canada

My next bike will be a ..ANFOB.....

It's All part of the ADVENTURE...

73 836cc.. Green, had it for 3 decades!!
Lost quite a few CB 750's along the way

Offline Spanner 1

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Re: How to shorten control cables? Anyone done it?
« Reply #4 on: October 14, 2009, 08:12:52 AM »
Good luck with trying to solder a cable-end on !....would you not lenghten the outer cable to take-up the slack with a piece of split tubing of the right size ?
If your sure it's a carb problem; it's ignition,
If your sure it's an ignition problem; it's carbs....

Offline 754

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Re: How to shorten control cables? Anyone done it?
« Reply #5 on: October 14, 2009, 08:31:32 AM »
Tubing would not fit properly..
 I have built cheater extensions for cables that do that, but fit better

 Machine a pce of round bar or hex, out of alum or brass, about 3/8 longer than you need to extend.  Should be around 1/8 bigger OD than stock cable.

 Drill the cable size hole with a bit of clearance. Turn one end down to match ferrule end on the od, the other end must be counterbored to fit ferrule inside. you can turn the od down if you desire on the part not counterbored. Now slit carefully with a hacksaw and cleanup with a small file.. install.
Maker of the WELDLESS 750 Frame Kit
dodogas99@gmail.com
Kelowna B.C.       Canada

My next bike will be a ..ANFOB.....

It's All part of the ADVENTURE...

73 836cc.. Green, had it for 3 decades!!
Lost quite a few CB 750's along the way

Walktex1

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Re: How to shorten control cables? Anyone done it?
« Reply #6 on: October 14, 2009, 03:56:50 PM »
If there is enough slack, simply put one loop in the cable, zip tie and wala!

Offline manjisann

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Re: How to shorten control cables? Anyone done it?
« Reply #7 on: October 14, 2009, 04:03:01 PM »
My cousin came over to help me do this but we ended up making it to short. As noted, all the lube and crud made getting good adhesion very difficult. I'm off to buy a new core cable and narp and I"ll try using some brazing rod, hopefully that will work.

Brandon
Sure it's for sale! How much you ask?? Well, how much are you willing to pay??? Now triple it, that's the price!

1973 CB500 K2 - Sold the bike and bought a Mig, Miss the bike, Love the Mig :D
1980 CB650 Custom
1971 CB500 Frame 650 engine: Project

Trip and General Ramblings blog: manjisann.blogspot.com

Offline Soos

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Re: How to shorten control cables? Anyone done it?
« Reply #8 on: October 14, 2009, 05:17:15 PM »
I mated some 750 carbs to my 650 and the pull cable on the carb is about an inch to long, even if I try to adjust the cable out. Has anyone done a custom shortening job? I was thinking I could cut the barrel end off, drill out the old cable bit, cut the cable to the length I want, and then use some electrical solder to "weld" it back together, would that work?? Since I haven't even had the bike running I'm trying to avoid getting a "custom" cable made.

Thanks,

Brandon


Try using cables from a CV cb650 carb rack......





Want some?
:)



l8r
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Just think to yourself what would Alowishus Devander Abercrombie do?
"Brix will be shat by your neighbors." - schwebel
(61mm)652cc 1979 cb650

Offline Soos

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Re: How to shorten control cables? Anyone done it?
« Reply #9 on: October 14, 2009, 05:19:14 PM »
Tubing would not fit properly..
 I have built cheater extensions for cables that do that, but fit better

 Machine a pce of round bar or hex, out of alum or brass, about 3/8 longer than you need to extend.  Should be around 1/8 bigger OD than stock cable.

 Drill the cable size hole with a bit of clearance. Turn one end down to match ferrule end on the od, the other end must be counterbored to fit ferrule inside. you can turn the od down if you desire on the part not counterbored. Now slit carefully with a hacksaw and cleanup with a small file.. install.


:)
(thats the machinists way out of that problem.....)


l8r
-=≡ Soos ≡=-
Just think to yourself what would Alowishus Devander Abercrombie do?
"Brix will be shat by your neighbors." - schwebel
(61mm)652cc 1979 cb650

Offline 754

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Re: How to shorten control cables? Anyone done it?
« Reply #10 on: October 14, 2009, 06:46:39 PM »
Yupp.. 16 min later you are smilin..


 the guy that ran to the dealer/partstore, is getting a story  with the words backorder or 4 working days delivery..

 manj if you are careful & good you may be able to trim the outer..
Maker of the WELDLESS 750 Frame Kit
dodogas99@gmail.com
Kelowna B.C.       Canada

My next bike will be a ..ANFOB.....

It's All part of the ADVENTURE...

73 836cc.. Green, had it for 3 decades!!
Lost quite a few CB 750's along the way