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I've done more than my fair share of half-assed repairs, but this one actually worked pretty well. I was surprised at least, figured I should share with the class. I wasn't really planning on documenting it until I realized it might actually work; so pictures are what they are. Here's my story:
Just about done with work I was headed back to the workshop to drop off my tools and call it a day. Just as I got out of the downtown area I felt a little pop on my clutch cable. Managed to drive it to the shop with no clutch as it was mostly back roads, but to get home I'd have to hit some major intersections that I really wanted a clutch to get through. Girlfriend couldn't give me a ride for 2 hours so I was stuck. Being surrounded by every tool that I own I did what any reasonable man would do and said "I can fix this. How hard could it be?" Best case scenario I got to ride my bike, worst case scenario I killed 2 hours futzing around with tools. Nothing to lose, everything to gain. It broke right near the connector thing that goes into the clutch lever, had a few strands left but they weren't enough to engage the clutch.
First attempt:
Copper was just there to keep the strands in tight, the plan was to solder it back together. It went poorly, I ended up melting the connector. But this inspired me. If a blowtorch can melt the connector, then surely it could melt a new one on. Ended up just cutting the old end off so all the strands were the same length.
Round 2:
This is the jig I made, I found a drill bit about the size of the clutch lever thing and drilled into the top. I drilled with one the size of the cable into it from the other side. I packed it full of plumbing flux and melted solder into it until it spilled out the cable hole. I then jammed the cable in and held the torch on the top until it looked like it was flowing into the cable. Cable is globbered with flux too, did my best to clean off the old cable lube with some random solvent **** I had laying around. I held it there till it seemed reasonably cool. Solder was 50/50 lead and something else, couldn't really read the label.
Cooling:
Cut away the wood with my pocket knife to get it out. Had to clean it up a bit with a file but for the most part it fit snug.
Final product:
Had zero slack left in my cable adjustments, had to tug pretty hard just to get it in. However I didn't have any clutch slip on the way home even running WOT up a steep hill. Might ride on it for a bit and just keep the new cable in my bag to see how it holds up. But there you have it, if you happen to breakdown with all your plumbing supplies, a drill and some scrap wood you can make a new cable end.
Just about done with work I was headed back to the workshop to drop off my tools and call it a day. Just as I got out of the downtown area I felt a little pop on my clutch cable. Managed to drive it to the shop with no clutch as it was mostly back roads, but to get home I'd have to hit some major intersections that I really wanted a clutch to get through. Girlfriend couldn't give me a ride for 2 hours so I was stuck. Being surrounded by every tool that I own I did what any reasonable man would do and said "I can fix this. How hard could it be?" Best case scenario I got to ride my bike, worst case scenario I killed 2 hours futzing around with tools. Nothing to lose, everything to gain. It broke right near the connector thing that goes into the clutch lever, had a few strands left but they weren't enough to engage the clutch.
First attempt:
Copper was just there to keep the strands in tight, the plan was to solder it back together. It went poorly, I ended up melting the connector. But this inspired me. If a blowtorch can melt the connector, then surely it could melt a new one on. Ended up just cutting the old end off so all the strands were the same length.
Round 2:
This is the jig I made, I found a drill bit about the size of the clutch lever thing and drilled into the top. I drilled with one the size of the cable into it from the other side. I packed it full of plumbing flux and melted solder into it until it spilled out the cable hole. I then jammed the cable in and held the torch on the top until it looked like it was flowing into the cable. Cable is globbered with flux too, did my best to clean off the old cable lube with some random solvent **** I had laying around. I held it there till it seemed reasonably cool. Solder was 50/50 lead and something else, couldn't really read the label.
Cooling:
Cut away the wood with my pocket knife to get it out. Had to clean it up a bit with a file but for the most part it fit snug.
Final product:
Had zero slack left in my cable adjustments, had to tug pretty hard just to get it in. However I didn't have any clutch slip on the way home even running WOT up a steep hill. Might ride on it for a bit and just keep the new cable in my bag to see how it holds up. But there you have it, if you happen to breakdown with all your plumbing supplies, a drill and some scrap wood you can make a new cable end.
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