How do make the throttle cable ends?

[Thruster87]

What methods are used to make both ends on new throttle cables [type of solder, brass fittings? etc ] but NOT the screw on clamp type. Cheers

 

 

[facthunter]

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...

 

 

[Thruster87]

Thank you for that I'll knock them up now over the weekend. I'm still curious to know if molds are used to make the large barrel stops/ends Cheers

 

 

[Thruster87]

A quick question on using lead free silver solders [comweld 965 ]instead of the 50/50 Any comments Cheers

 

 

[facthunter]

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...

 

 

[Thruster87]

Found this info

 

50/50 Solder

 

Cored Wire Reels — Orange Label

 

Sticks — marked 50/50.

 

JOINING PROCESS:

 

Soldering only.

 

SOLDERING IRON bit temperature: 272°C.

 

TYPICAL ROD ANALYSIS:

 

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

 

TYPICAL PROPERTIES:

 

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.

 

JOINING PROCESS:

 

Soldering only.

 

SOLDERING IRON bit temperature: 281°C.

 

TYPICAL ROD ANALYSIS:

 

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

 

TYPICAL PROPERTIES:

 

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

 

 

[facthunter]

Solders.

 

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..