Making control cables?

[rcx132]

I've been reassembling my Suzuki Vitara, it's had 3" suspension lift and one of the problems the lift has caused has been that the handbrake cables don't reach the axle when the axle is at the bottom of it's travel. Usual solution is to undo the middle locating clips so that the cables can basically short cut. But this means they now flap around and rub on the suspension links.

I think I read that you can make own control cables by cutting to length and silver soldering the nipples onto the ends. Does this sound right? My friend has a lathe so can make the nipples. I've never silver soldered but can't be too hard, I have an Oxy-MAP torch.

 

[Ruffian]

Does it have 1 into 2 bias rod in the handbrake?
As had to extend on a frontera before and just used m8 threaded and a couple of joiners and moved the cables back 8 inches for extra room.

 

[CompoSimmonite]

Due to forces involved soldering might not be sufficent as they are normally swaged. A marine (sailing) chandler should be able to able to swage the apprpriate end fittings.

 

[8ob]

Venhills in Dorking do all this cable making malarkey https://www.venhill.co.uk/

They also do a box of tricks for making up your own, cant remember the last time I had to but a new cable, has saved the day on many occasions. The end of the cable gets frayed/splayed out in the ferrules so they dont pull through when soldered

Bob

 

[optima21]

Ive shortened handbrake cables before by making a new nipple and just mig welding the cable in the nipple.

 

[Ton-up]

I,ve had excellent service from SpeedyCables in the past.

http://www.speedycables.com/m.index.html

 

[rcx132]

Does it have 1 into 2 bias rod in the handbrake?
As had to extend on a frontera before and just used m8 threaded and a couple of joiners and moved the cables back 8 inches for extra room.

The bias bar is at the handbrake lever, don't think there would be space to extend it there.

@8ob with that kit, are the cables silver soldered in? Or regular lead solder?

@Ton-up I'll give them a call, were they expensive?

 

[Robotstar5]

If you make up your own, just make sure it's good, you wouldn't want your car rolling away if it failed

As above, Venhill are very good, they will make them to your dimensions.

 

[rcx132]

If you make up your own, just make sure it's good, you wouldn't want your car rolling away if it failed

As above, Venhill are very good, they will make them to your dimensions.

If Venhill or Speedycables are affordable then I'll just send them my old cables and ask them to make new ones three inches longer

 

[Ruffian]

I'm still in discussion with venhill over my zx10 throttle cables, sent them back the first time and got to go back again.

 

[Ton-up]

@Ton-up I'll give them a call, were they expensive?

I last used them a couple of years ago and they wern't cheap i,m afraid.

 

[rcx132]

Found a cheaper alternative, these guys autodoc.co.uk do aftermarket cables and a lot of these aftermarket cables are 5 or 10 cm longer than the original cables, just enough to compensate for my suspension lift.

BTW has anyone else found autodoc.co.uk ? There seem to be a few companies like this appeared, they all operate from Germany and are seriously cheap, I just had a Blueprint cambelt kit from them and it worked out a third of what Euro Car Parts wanted, I've also had a Nippart wheel bearing from them, also fraction of UK price. I've also found a company in Japan that sells OEM parts at about a third of what the UK dealer wants, although shipping is £20 haven't used them yet.

 

[wristpin]

Due to forces involved soldering might not be sufficient as they are normally swaged. A marine (sailing) chandler should be able to able to swage the appropriate end fittings.

Not sure about handbrake cables but for bikes, motorbikes and lawnmowers etc the nipples have a "wide side". Pass the cable through and splay the ends of the strands into the wide bit and fill with solder to make a wedge. its the wedge and not the adhesion of the solder that does the work. I always use Bakers Fluid and old-fashioned stick solder.

 

[zx9]

BTW has anyone else found autodoc.co.uk ?

Yes, they are a right pain, I spent ages putting together an order of spares for my 1999 Audi A4, all well and good till I get to the check out and guess what they can not ship large items to the UK. I phoned their free phone number and had a rant at them, they could not grasp that a UK IP address would probably involve shipping to the UK so why let me add items to the basket that they can not ship. Made a note to never try to shop with them no matter how cheep they are.