Marcus Bowden banana-man
A few MPH's ago
For the benefit of all members as there has been quite a lot about making cables on the forum of late and the differing qualities of solders / fluxes. This is a method I have used and does not even
require solder !!! Solder-less is usually a longer nipple/trunion and threaded along the axes for a clamping screw
& often found on French bikes, Herve' 002 frequently used it until he was enlightened in the late eighties.
The method I use I first found on the front brake cable of my "B" rap whilst salvaging parts (was it original works?) in the mid sixties (apprenticeship years, not much cash) so I made a punch and experimented. I've made a few gigs & cables since.
Equipment:- thick aluminium vice jaws, clamp in vice and drill vertical holes through the mating faces slightly smaller than the cable, then drill a hole the recess size of the nipple
Turn down piece of silver steel into a hollow punch form (1% carbon which is easy
to harden) with a hole drilled to a depth & diameter of diameter of the cable, radius the end inside & out so not
to cut the cable, heat to a cherry red and quench in water. Different size for each size of cable.
Place the cable between the jaws leaving about 3 to 4 diameters above the jaws, using the punch to retain all the ends together deftly hammer the cable into the nipple sized hole.
This will never pull out as it is self cleeting. Solder to finish as it holds it together & austhetics
Bowden is the cable also my name but no connection!
PS When doing the last nipple ensure all the various outer's & adjusters are in correct position, we've
all done it wrong once or may be twice!
The reply to thread does not want to take the picture of the punch, vice jaws & samples of cables but if you have MPH's you will find it.
Small cables of throttle & choke I use silver solder with the very fine flexible cable & hard solder a long blob before cutting it in the centre then with file or grinder shape it into nipple for the carb end then throttle end where it is just soft soldered,cut , into nipple and use a hollow punch again and one can still create an inverted mushroom of smaller size.
JAWS WITH DIFFERENT CABLE SIZES TEST PIECES & PUNCH