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How do make the throttle cable ends?


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Cable ends


Thruster87, Get some brass stock about 5/16" dia and make your own ends. It is essential that a countersunk hole be formed on the outside end of each fitting and the strands of the cable inner be forced outwards into this countersink at the time the soldering operation is performed, to prevent any chance of the cable pulling through. The end of the cable should be tinned carefully prior to inserting it into the end fitting.


Use 50/50 tinmans solder, and file off the excess cable with a fine file after soldering. Wash the cable end with warm water to remove flux as it is corrosive. Nev...



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Cable ends.


It's a whole new concept to use silver solder as you have to heat the whole thing to a dull red heat where you have the chance of burning the pieces (oxidising) and softening the wire in the cable. You don't run this risk if you use tinman's solder as you will use a soldering iron instead of a flame. I strongly recommend the soft solder technique (with the spreading of the strands guaranteeing no chance of the wire pulling through).N...



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Found this info


50/50 Solder


Cored Wire Reels — Orange Label


Sticks — marked 50/50.




Soldering only.


SOLDERING IRON bit temperature: 272°C.




Sn: 50% (Tin) Pb: 50% (Lead)




Tensile Strength 45 MPa


Shear Strength 40 MPa


Approximate Melting Range 183–212°C


Electrical Conductivity 10.9% IACS Comweld 965 [soft silver]Blue Labels and backing cards.




Soldering only.


SOLDERING IRON bit temperature: 281°C.




Sn: 96.5% (Tin) Ag: 3.5% (Silver)




Tensile Strength 60 MPa


Density 7.5g/cm3


Approximate Melting Point 220°C


Electrical Conductivity 17% IACS


COMWELD 965 Solder is a tin / silver eutectic solder which has the highest strength of all


soft solders. Due to it’s high strength, good electrical and thermal conductivity, non toxicity


(lead, zinc and cadmium free) and also the fact that it remains bright and shiny, make


COMWELD 965 Solder the most universal of soft solders. Comweld 965 Solder is used for


the joining and repair of copper, bronze, brass, nickel, monel, steel, stainless steel, pewter,


chrome plate, metal sculpture, model making, costume jewellery and or a combination of


metals with the exception of aluminium and magnesium



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965 would be fine as That solder is still low temperature melt. The common silver solders (and there are quite a few) are used by plumbers to connect copper pipes in hot water systems and refrigeration, through to others which are used to make jewellery ,are applied with a flame, and are done at a dull red heat,and are referred to as hard solders ,have a cost variation relating to the percentage of silver. With 965,the temperature of the "iron" (which is used to apply the solder & is actually made of copper) is very little above the 50/50 tin lead alloy requirement so you should have no problem. If the job is done properly, the main load is in shear. Use the appropriate flux., absolute cleanliness , and in some alloys (due to their fluidity) a close fit, or some sealing (clay) may be needed to stop the solder flowing through the joint.


Hope this is of some help N..



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