how do you solder them? is it the same kind of solder you'd use in wiring, or plumbing, or is there another kind needed? or is it not that at all?

i gather you'd use a blowtorch instead of a soldering iron

where can you get the ends to solder on?

I have used electrical solder to solder small cable ends on...

Plumbing solder for larger stuff... no idea what the difference is betwee the two..


You WILL need a good flux and a blow torch....

plumbers solder; electrical is not strong enough,and melts at lower temperature, hence the blow torch.

you would use a blow torch, or even a gas ring on a cooker if careful.

you can buy the brass nipples (as they are called) from VWP. They also sell nipples with grub screw fittings as well as cable in different diameter.

Or make them yourself from brass rod - B&Q sell them.

the nipple should have a countersunk and the ends of the cable opened out and splayed before soldering - helps prevent the cable being pulled out.

[Edited on 28/4/09 by 02GF74]

You need proper tools to do this correctly.

What you are after is called a soldering pot machine.

It is a small pot full of soldering. It is heated up so it is in a liquid form. You flux the end of the cable and then dip it in the soldering pot.

Was looking to get one yesterday.

plumbing solder it is then! i wasn't sure if there was any difference. i'd have thought they'd be more welded than soldered

i'm struggling to find a handbrake cable long enough for my car. unsurprisingly, my car's longer than a sierra someone suggested the universal cable kit from Hein Gericke, but they're only 2m long, i really need one cable to be almost 4m the other about 2.5m (handbrake lever won't be in the middle of the car)

so i've bought a handbrake cable from an astra van (look the same caliper ends as the sierra one) to consider modifying. it was only £3

speedycables wanted about £35-45 + vat and post for EACH cable.

quote:

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Originally posted by l0rd
You need proper tools to do this correctly.

What you are after is called a soldering pot machine.

It is a small pot full of soldering. It is heated up so it is in a liquid form. You flux the end of the cable and then dip it in the soldering pot.

Was looking to get one yesterday.

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If i would get the one on ebay atm at 599 quid, i would have to charge you 34.99 per cable free p&p

this is what you want

http://www.rapidonline.com/Tools-Fasteners-Production-Equipment/Soldering-Equipment/Soldering-Irons/Solder-pots/73129/kw/85-1050?source=googleps&u tm_source=googleps

£34.99 with free p&p, well, its cheaper than speedy cables...

i guess any sort of crucibel ( i think thats what they're called, if i remember school chemistry all those years ago) of solder heated with a blowtorch should do it?

i found the nipples (he he) on VWP, looks like it might come together, as lng as this astra van cable is long enough

quote:

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Originally posted by l0rd
this is what you want

http://www.rapidonline.com/Tools-Fasteners-Production-Equipment/Soldering-Equipment/Soldering-Irons/Solder-pots/73129/kw/85-1050?source=googleps&u tm_source=googleps

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When i failed first SVA on handbrake, tester was very critical to explain he would not accept home modified cables. He wanted to see either shop bought cable kit or if they were custom made ones evidence of what equipment was used to press the ends on including forces used etc. I used Allegro cables in the end that were just about spot on and came pre-made with the correct ends fitted. Unfortunately the steel brackets (U shaped bits with cable slot) were too weak and distorted, got through by adding a jubilee clip around them to add strength.

Incidently - the original fail was because i used std sierra cable that was cut and re-joined used 2 clamps at either side of the quadrant - however i believe this joining method was since deemed to be acceptable by VOSA (not sure if it carries over to IVA though).

^ ah, that is interesting.
its funny though how you can build a chassis yourself, make a fuel tank, plumb it all in, but they don't like a modified handbrake cable.

the problem i have is there is no way i can mount the lever to the tunnel. it must go to the right of the driver seat. add to that, the back wheels are further away than most cars, the cable from the rear left wheel to the lever will be about 4m, and the other one about 2.5m. because its not in the centre i can't use a standard cable. i need 2 seperate cables. we'll see how i get on with these astra cables. they might be alright lol knowing my luck though, they won't be

quote:

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Originally posted by DarrenW
When i failed first SVA on handbrake, tester was very critical to explain he would not accept home modified cables.

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I made an accelerator cable/nipple some time ago. The old sierra cable had snapped at the pedal. The ball type nipple. I drilled out the old cable at the ball end and used a blow torch with silver solder (maplins cheap) to fill the hole and solder in a pushbike cable.
Strong as you like. Try not to directly flame the cable though.

I did mine with silver solder.

With the spare bit I made up a test piece and tested it to destruction.

It broke at 330kgs so in theory I could lift my car by the handbrake cables.

Cheers
Paul G

quote:

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Originally posted by Staple balls

£65?

I'm sure a couple of bits of pipe and a blowtorch would do the job for about £64 less.

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Damn right. I strongly believe in doing a job wrong, or not doing it at all

Edit: haha, didn't realise that was my sig.

[Edited on 28/4/09 by Staple balls]

I made a steel nipple for my handbrake cable and drilled it to fit the cable then countersunk one side.I then put the cable through and splayed the end out before welding it with my mig on a low setting.
If silver soldering you need to be carefull not to overheat the cable and I dont think soft solder would last long for a handbrake cable.
Paul.