Commando front brake.

My friends and I are the opposite. We do not trust anyone but our own cable manufacture.

I personally have had two commercial nipples pull through on my Commando (one a throttle and one a rear brake) and will not trust my life to some random person on the other side of the world.

We make the nipple properly with a small and larger hole drilled and then reverse each strand back to create a birds nest in the larger hole.

As Rob said the solder on the birdsnest maintains the larger balled shape so it cannot pull through the smaller hole.

We have raced bikes with cable activated brakes for around 50 years with no issues.
John, we seem to be on the same page, except...
I gave up mid-cable switches years ago. They, to me, make the brake spongey and uncertain.
I now fit a micro switch from Magura (get them from Venhills) that fits under the lever bracket and closes when the lever is pulled. Obviously it is a normally open switch.
I've posted some pics a few years ago - I'll see if I can find them. 👍
Cheers
 
John, we seem to be on the same page, except...
I gave up mid-cable switches years ago. They, to me, make the brake spongey and uncertain.
I now fit a micro switch from Magura (get them from Venhills) that fits under the lever bracket and closes when the lever is pulled. Obviously it is a normally opyen switch.
I've posted some pics a few years ago - I'll see if I can find them. 👍
Cheers
My street bikes are all hydraulic these days except for the rear brake of my Commando which doesn't have an inline switch. So no experience there.

The brake cables I'm talking about are on my racing Dommie, and friends Velo and 7R race bikes. Photo is of one of the Velos ridden by Bill Swallow about 8 years ago. Cables all done by hand. Not that Bill uses the brakes much on the little 250 Eldee Velo.😎
 

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My friends and I are the opposite. We do not trust anyone but our own cable manufacture.

I personally have had two commercial nipples pull through on my Commando (one a throttle and one a rear brake) and will not trust my life to some random person on the other side of the world.

We make the nipple properly with a small and larger hole drilled and then reverse each strand back to create a birds nest in the larger hole.

As Rob said the solder on the birdsnest maintains the larger balled shape so it cannot pull through the smaller hole.

We have raced bikes with cable activated brakes for around 50 years with no issues.
Hi Merv, I understand why you do it, and the theory behind it, but I guess as I've never really been shown how to do it properly I err on the side of caution. I've actually learned a bit from this thread though, which is good 👍
 
Hi Merv, I understand why you do it, and the theory behind it, but I guess as I've never really been shown how to do it properly I err on the side of caution. I've actually learned a bit from this thread though, which is good 👍
Hi there. We must have meet somewhere in Europe perhaps as you know my second bike racing name. 🤣🤣🤣

Nick the Velo builder basically taught me his methodology. It critical to get the two hole sizes correct. One a firm fit on the wire cable and the second big enough to fully retain the turned back birdnested cable strands.

Nick uses a pair of fine needle nose pliers and turns every strand back on itself one by one carefully creating a ball of wire that fills the larger hole. He can take an hour or more to carefully do a brake cable nipple. Then clean everything in a flux. Then hold the nipple in a vice and pull down on the cable getting the strands perfectly bunched into the large hole in the nipple. Then use what we term silver solder. About 3 or 4 % silver content solder using a large soldering iron.

A cable made this way is 100 % reliable but of course still checked for every race meeting.

I have found commercially made throttle clutch and most critically a rear brake cable which had no birdsnesting of the wire whatsoever. I cannot name names because I simple don't remember the manufacturer. It was maybe 20 plus years ago now but I still will only do my own cables.

Doing a set of twin throttle and choke cables is very tedious but unfortunately still necessary in my experience. I still remember the look of misery on Nicks face as their very first Velo KTT came to a halt half way through its first race at the very first meeting. The nipple pulled off the commercial throttle cable. 🙄

For carbs the nipples in the slide are very small but provided you can get at least 2 or 3 stands reversed into the nipple a throttle cable will be strong enough plus your life doesn't depend on it anyway.
 
Hi there. We must have meet somewhere in Europe perhaps as you know my second bike racing name. 🤣🤣🤣

Nick the Velo builder basically taught me his methodology. It critical to get the two hole sizes correct. One a firm fit on the wire cable and the second big enough to fully retain the turned back birdnested cable strands.

Nick uses a pair of fine needle nose pliers and turns every strand back on itself one by one carefully creating a ball of wire that fills the larger hole. He can take an hour or more to carefully do a brake cable nipple. Then clean everything in a flux. Then hold the nipple in a vice and pull down on the cable getting the strands perfectly bunched into the large hole in the nipple. Then use what we term silver solder. About 3 or 4 % silver content solder using a large soldering iron.

A cable made this way is 100 % reliable but of course still checked for every race meeting.

I have found commercially made throttle clutch and most critically a rear brake cable which had no birdsnesting of the wire whatsoever. I cannot name names because I simple don't remember the manufacturer. It was maybe 20 plus years ago now but I still will only do my own cables.

Doing a set of twin throttle and choke cables is very tedious but unfortunately still necessary in my experience. I still remember the look of misery on Nicks face as their very first Velo KTT came to a halt half way through its first race at the very first meeting. The nipple pulled off the commercial throttle cable. 🙄

For carbs the nipples in the slide are very small but provided you can get at least 2 or 3 stands reversed into the nipple a throttle cable will be strong enough plus your life doesn't depend on it anyway.
Yes, we met on the Island last year in the Kiwi tent🏍🏍🏍😉

Thanks for the info. on the methodology 👍
 


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