How to Solder Throttle and Brake Cables

A brilliant and straight forward technique to solder cables. Old school technology at its best.

Re: How to Solder Throttle and Brake Cables

I think this Bairdco approach is way cleaner and easier in the long run. Probably success every time.

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Re: How to Solder Throttle and Brake Cables

I didnt know Baird's game was cold like that

Re: How to Solder Throttle and Brake Cables

I buy that knarp pack from the auto parts store and just solder them on for big stuff like brakes. I make the tiny carb ones from scratch.

Re: How to Solder Throttle and Brake Cables

Ha! When I saw the title I thought, "I wonder if I can find that pic from ten years ago" with the mold thing I made...

I started doing that with motorized bikes, because the kit throttle cables were like 2' too long.

I made that from a piece of aluminum about the same thickness as a cable end.

Used a band saw to make a groove for the cable to fit in.

Drilled a tiny pilot hole all the way thru, then a bigger hole the size of the end almost all the way through.

Clean the cable, lay it in the slot, then smash the cable a bit to unravel it.

Use a bernzomatic torch to melt the solder, let cool, and file the top while it's still in the mold.

Use a spring-loaded punch in the tiny hole in the bottom to pop it out, cut the excess cable, and file the end if necessary.

Pretty simple.

I made this back before I could find cable knarps. I didn't know they existed. Now I just use those, unless I run out and need a cable right away.

I originally posted the how-to on a motorized bike forum, but it's been shared to motorcycle forums, and other places, so that's my legacy...

Re: How to Solder Throttle and Brake Cables

Also, when I first did this, to test the strength, i used a vice, opened enough so the soldered end sat on top, with the cable hanging down (so nothing was squished in the vice,) then wrapped the loose cable around a piece of pipe, and used all my weight on the pipe to try to yank the soldered end off. Didn't budge it. Never had one come off.

Re: How to Solder Throttle and Brake Cables

I googled “cable end mold” thinking there would be something like a lee bullet mold for cable ends.

Your mold was one of the first things that popped up.

Re: How to Solder Throttle and Brake Cables

> baird co Wrote:

> Ha! When I saw the title I thought, "I wonder if I can find that pic

> from ten years ago" with the mold thing I made...

> I started doing that with motorized bikes, because the kit throttle

> cables were like 2' too long.

> I made that from a piece of aluminum about the same thickness as a cable

> end.

>

> Used a band saw to make a groove for the cable to fit in.

>

> Drilled a tiny pilot hole all the way thru, then a bigger hole the size

> of the end almost all the way through.

>

> Clean the cable, lay it in the slot, then smash the cable a bit to

> unravel it.

>

> Use a bernzomatic torch to melt the solder, let cool, and file the top

> while it's still in the mold.

> Use a spring-loaded punch in the tiny hole in the bottom to pop it out,

> cut the excess cable, and file the end if necessary.

> Pretty simple.

> I made this back before I could find cable knarps. I didn't know they

> existed. Now I just use those, unless I run out and need a cable right

> away.

> I originally posted the how-to on a motorized bike forum, but it's been

> shared to motorcycle forums, and other places, so that's my legacy...

Lol i am actually rebuilding a motorized bicycle engine and the only thing left to do is set up a throttle cable. I ordered it like 6 months ago but with covid its really delayed.

Re: How to Solder Throttle and Brake Cables

A lighter and some flux.

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