Sunday, March 10, 2019

Red: Venhill Custom Throttle Cable

Had really been dreading this job so decided to say to hell with it and just go for broke.

Took me awhile to get my head around the old notes, but luckily I'd done all the heavy lifting on the measurements.  The stock throttle cable has 87mm of cable coming out of the sleeve.  I calculated I'd need 110mm for the custom job.  (But needed to leave some excess in order to do the solder)

Laid the cable out on the yardstick and clipped it in place to do the final measurement.

Then cut the cable, made the "bird's nest" on the nipple, heated up the soldering pot.  From old notes, I knew you can't let the flux creep too far up the cable, so was cautious about that.  Once the solder hit full temp I gave it a couple dips. 

Went down to test it on the throttle and realized that the nipple is a pretty tight fit in the first place and there can't really be very much excess solder on it otherwise it's just way too big.

So filed down the solder until it fit.  Thought, "That wasn't so hard..."

Went to install the carb-side end and only then did I realize that the ferrule on that end was too big for the carb!!

I'd totally forgotten that there were two sizes of ferrule and I'd use the large instead of the small.  Luckily, the cable's overall length was probably a bit too long, so I can chop the whole thing down and redo the ferrule.

Next time:
  • Make the bird's nest smaller and tighter so there's not so much excess solder
  • Since you can't thread the cable and have it come out of a set ferrule, and since the throttle end nipple is already set, may need to cut off the pre-done ferrule and replace that side with the small ferrule instead.
    • Cut off the ferrule that comes pre-installed.
    • Install the small ferrule on one end.
    • Thread the cable through that so that the carb-side nipple is on the same side as the small ferrule.
    • Install the larger throttle-side ferrule on the other end.
    • Cut to correct length and solder.
  • Need to check how the cable is going to be routed to set the final length.  But better to have it a little too long so that it's possible to adjust if needed.










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