Making Brake cables for a Car.

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tekfab:
You say "prohibitively" expensive ? have you tried a local yacht chandler/Rigging company ? boats use wire rigging from 2mm - 20mm (and bigger) and should be able to do whatever you need. You might need to have a look at their suppliers catalogue to find an end more suitable to your use. I did boat rigging and also architectural wire work and there's an awful lot of fittings available and the cost is not that much, but i suppose it does depend on your means.
What diameter of wire are you using ?

Mike

vtsteam:
1.) you need to own a load tester and cycle the cables and understand and prove yield, fatigue etc.
2.) you need to do accelerated aging testing to determine the effect of moisture and vibration on the materials you use and the plumbers flux which will remain in your strands after your "soap and water" removal method.
3.) you might want to find out the actual measured temperature of your solder pot and compare to the tempering temps for the materials you will be using.

Putting a cable into and standing on the brakes a few times isn't "testing".

What happened to, "Ether that or Ill find a suitable shop who can put the ends on."

and, "New cables are not available so I will go to Speedy Cables and get some custom made."

A liability lawsuit could be a lot more expensive than properly swaged cables if word ever got out you'd done this after an accident -- even if the cables didn't break. And i expect when you have your car inspected and when you sell the car you will of course reference your plan here.

vtsteam:
What kind of car is this and what kind of cables? Maybe we can help you solve this availability problem with a little research.

tekfab:

--- Quote from: vtsteam on September 13, 2013, 07:44:54 AM ---1.) you need to own a load tester and cycle the cables and understand and prove yield, fatigue etc.
2.) you need to do accelerated aging testing to determine the effect of moisture and vibration on the materials you use and the plumbers flux which will remain in your strands after your "soap and water" removal method.
3.) you might want to find out the actual measured temperature of your solder pot and compare to the tempering temps for the materials you will be using.

Putting a cable into and standing on the brakes a few times isn't "testing".

What happened to, "Ether that or Ill find a suitable shop who can put the ends on."

and, "New cables are not available so I will go to Speedy Cables and get some custom made."

A liability lawsuit could be a lot more expensive than properly swaged cables if word ever got out you'd done this after an accident -- even if the cables didn't break. And i expect when you have your car inspected and when you sell the car you will of course reference your plan here.

--- End quote ---

LMFAO He's not in the USA where they sue anybody for anything and do you think the original car builder went through all those tests ? ;-)

Mike

vtsteam:
I think the swage fitting, cable supplier, and swage tool manufacturer sure did.

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