Custom Cables and Ends from scratch or FIX - Throttle Brake Clutch

Throttle, Brake, clutch and so much more.
Stuff I used in the video:
Inner Cables 1.5mm/1/16" zinc coated steel: amzn.to/3sgFeTS
Instant start torch head: amzn.to/46UAuT5
ACID plumbing flux: amzn.to/46Qu4ED
Solder 40/60 (60% lead) : amzn.to/45QErXt
-Some links are commissioned where I may make $0.02cents. But it's all stuff I bought myself or identical.
FIY ABOUT SOLDER: Use a solder with high lead content. It is better for repairs but also a great electronics solder. If it has rosin core(hard to find without) it doesn't matter, but you will need an Acid Flux(Zinc Chloride) for bonding to steel and oxidized metals. You can later use the solder for electronics only repairs with the built in rosin flux. You can use acid flux on electrical stuff(especially corroded/oxidized) but you have to clean it off after you're done.
SUPPORT THE CHANNEL or support the SHOP DOG's treat addiction:
Buy Ginger a new bone: www.paypal.com...
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Ginger's Christmas Wish List: www.amazon.com...
65 Ford 65Ford SFF

[@69uremum]

The end of the cable that goes into a brake lever for example, it is called a knarp. The sleeve that goes over the sheath is a ferrule. If you are going to use a solid brass or steel knarp, I've found the best way is to silver solder it, the radnor kit that comes with the flexible kind of solder is very good for doing this kind of work.

[@MaxGiganteum]

"The sleeve that goes over the sheath is a ferrule"... 100% correct. It's amazing how many folks don't know the correct term for it although it should be noted that a ferrule can take different forms other than a round, thin walled and narrow sleeve shaped object. "Ferrule" was never well defined IMHO and became somewhat of a loose descriptor for all sorts of objects that were generally used simply to hold a part or parts together. I was originally introduced to a ferrule as a youth when I used one to join a threadless tube to a base via a compression fitting but I eventually came to understand that a ferrule can be all sorts of bits used in a variety of ways. Generally, I think of the term as a slang term and have for quite some time. I bring this up because it's important to ensure you know what you're getting if you go to buy replacements... it's important to visually confirm what you're getting is a match for what you want. This is especially true if you don't like making multiple trips to a supplier or having to return items that were shipped to you but turn out to be unusable. Just as it's wise to take any part you wish to replace to an auto parts store so you can match up the old & new parts, compare your ferrules and measure one out with precision measuring tools if necessary. While it may not make any real difference, sometimes it does - such as when you make or repair pressure connections for pneumatic lines, hydraulic lines, fuel delivery lines, etc. Best wishes! - Max Giganteum

[@69uremum]

@@MaxGiganteum exactly, i learned about ferrules from working on mopeds and also ferrules for electrical work:)

[@helmet098]

Gee gad Brain, how do fit a shark in a swimsuit NARF

[@probegt75]

This is ingenious. I need to shorten a clutch cable for a custom built quad and this randomly popped into my feed. I swear google/youtube can read our thoughts.

[@mikehunt8375]

No doubt, I was working on a throttle on my bike last night. I've never watched this man's channel before, I didn't even have KZbin on last night after I got home from work. Just woke up this morning to watch some KZbin and the 3rd line down, this video. I thought to myself, "strange this popped up", then I read your comment and well, it must be listening to us... I mean come on what are the chances? It happens all the time! I already threw all my TV's out, looks like the phones and tablets are next. Most think that's just ridiculous, I ask you, when was the last time you had one of your own thoughts? If you still could be honest with yourself the answer SHOULD scare you...

[@davidbasil5734]

You rite

[@rstole]

The last time I had my own thoughts was a few years ago. The doctor gave me some new meds and they all went away.🎉

[@troye.1309]

Me and my brother used to do this in our teens because we never had money for new. We would pick up bikes and push mowers at the dump to fix and re-sell.

[@mudgyver5205]

We were equally as poor when we were kids. Not having money forces one to come up with ideas that to this day are useful in life.

[@og.nohaze7740]

@@mudgyver5205 your name is very fitting to this conversation lol

[@glenmchargue5461]

Man... I'm such a softee for dogs. I love seeing people being nice to their dogs.

[@chabat124]

Nice. Fixing something that would otherwise end up in the landfill. For me and others, fixing something is so satisfying. Especially in a world where everything is mostly disposable. Fixing stuff is the "Green"-est thing you can do for the planet, but that's never talked about. Thanks for making this video, I learned something new today.

[@oscara.8176]

Never tired of watching you doing tricks. :)

[@sixtyfiveford]

Hey thanks

[@AtimatikArmy]

Oh man this is a classic style sixty five ford video! No-nonsense straight up common sense. I don't know what the modern world would do without you... Good stuff, love it!

[@sixtyfiveford]

Hey thanks.

[@andrewpate9157]

Dude, I gotta say the most impressive part was the jerking and weight you put on cable with the vise. I wouldn’t have thought it would hold that well. Great job and thanks for sharing.

[@yodasbff3395]

You're a man after my own heart, your work never fails to enlighten people 👍. Ginger is a sweetheart, we need more Ginger. 🥰

[@justinberry6160]

the stress test was AMAZING lmao! great video!

[@sixtyfiveford]

Glad you liked it!!

[@giggitygiggitygoofg6069]

I went to the scrap yard/ junk yard & I removed a dozen cables from 7 or 8 different cars. I took the trunk release cables, the fuel cap release cables and some bonnet/ hood release cables the reason I got these particular cables is cuz they are between 3 to 5 metres long and pretty strong which means I can pretty much make any size cable 4 all & any projects I'll ever need. Hopefully Just a helpful little tip for anyone who builds motor cycles or go carts . .

[@sixtyfiveford]

Great source!

[@Dannyvirk]

Thank you very much, i've used other methods before, but it was always hit or miss. This looks really good. As a rider of 80's bikes this is the sort of stuff you need to know to keep them running on a budget. Cheers

[@markyedlicka]

regardless of how much I think I know, its just about a guarantee I'll learn something new watching a sixyfiveford video

[@sixtyfiveford]

Hey thanks

[@joshgreen2164]

That the truth.

[@MaxGiganteum]

From approximately 5:45 to 11:00... the method you're using is called "potting" a cable. I'm specifically referring to using a mould filled with a molten metal to form the grip at the end of the cable. The key to strength is the frayed ends of the cable strands being surrounded randomly by the poured metal so that no slippage can occur. As for the metal, some solders are usable as is lead, copper, bronze, brass, aluminum, etc though I'd stay away from aluminum as it seems to have durability issues - a lack of ductility. Obviously, solder is easy to melt as is lead but if you have access to an oxy acetylene torch, you've got a lot of options for metals to use if you're in a pinch. An old school penny works quite well for example... pennies minted from 1944-81 are about 95% copper making them viable for the process. Of course you can strip some copper wire, use empty brass shell casings, snag a bullet or some wheel balancing or fishing weights for their lead or scrounge up whatever you can find if you're in a tight spot. If push came to shove, you could use gold or silver too with a torch. Anyway, for those that can do it, I recommend machining up a permanent mould out of steel. While wood works, you typically kill it removing your newly minted cable. Manufacture a steel mould with a push rod in it to eject a fresh pour then you'll have one for life. Best wishes! 👍🏻 🛻 👨🏻‍🔧 - Max Giganteum

[@mikecollins8241]

Awesome trick! There have been a few times I could have used this, and saved waiting for days/ weeks to get whatever random project going again :) In fact, I got the incorrect kill cable for one of my mowers, now I can redo it and not have to order another/ waste the wrong one!

[@sixtyfiveford]

It's a handy little trick.

[@mikecollins8241]

@@sixtyfiveford and now I'm thinking of a way to make a mold that is reusable.. maybe a piece of aluminum , cut in half, then drilled.. clamp onto cable, pour full and remove.. like a bullet mold for reloading.. only for cable ends :)

[@kmatikzofficial]

This was one of the best videos that I’ve watched on KZbin. Partly because I really wanted to know how to do this for years now!! Thanks so much for making it!

[@lmenzol]

Ok so towards the end I was like “wtf are you doing” but once I saw that you made a mold from the wood my jaw dropped at how genius this is. Bravo 👏

[@TheRaiderCritique]

Last week I had two Husqvarna lawn mowers of the self-propelled just break at the same time pretty much. 1 yd apart. And I happen to stumble across this in my ventures at night trying to find a quick solution and this worked like a charm thank you so much I'll never buy another lawn mower cable from a lawn mower shop again

[@89G]

Very useful info! Thank you my friend!

[@sixtyfiveford]

Thanks man

[@2LateIWon]

Yes I think most people forget to clean the cable. As always great video 👍

[@johnomelia2991]

Great stuff, thanks. I need a bowden cable for the window in my 2000 Mercedes and it’s $50 for a pair. This is fantastic

[@shaun7057]

Man I miss my red heeler he was the best dog I’ve ever had and when he left this earth he took a huge part of me with him!! Makes me happy to see others have the same love for that breed of dog they truly are the best! And if anyone approached my boys that I wasn’t ok with my dog made it crystal clear that whoever it would have been wasn’t welcome and that they needed to get moving lol rip brave

[@sixtyfiveford]

I don't think people understand what they're missing when you get a dog with personality and smarts.

[@shaun7057]

@@sixtyfiveford it’s an incredible bond that you can’t get anywhere else from no other living creature the down side is when it’s time to day goodbye. It’s been just over 2 years since I lost my red heeler and I have a hard time every day still without him. I obviously don’t show it especially to my wife and kids but I definitely struggle with him being gone. But that’s why you are supposed to make every day you have with them count

[@cliffpalermo]

Of course you post this now. I was installing a new throttle cable on my kids go kart direct from Trinidad and the barrel broke off the end of the cable, already ordered a bolt on version will try this one day

[@hadesomegamoto7639]

Awesome thanks for making this video it worked pretty well. I was making a custom cable and needed to change one of the ends of a throttle cable to work with a clutch lever. Worked great!

[@johndoe43]

I'm pretty sure ginger likes to go for a ride. Good video and idea.

[@racerxonthe8th]

Awesome! I had to shorten a brand new '69 Mustang cable. Trying to figure out how to put a new end on it. Going to try this. Thank you!

[@phillyfathead]

Excellent!

[@sixtyfiveford]

Hey thanks

[@SooSmokie]

Sweet tip! Love these types of tricks.

[@senatorjosephmccarthy2720]

Great idea on making the mold, Now. I've made a ball end, but if a next time is needed, now I know how to make a cylinder. Thanks!

[@lalmuanpuiamizo]

The outcome is much better than i thought it would be, thank you

[@sixtyfiveford]

If you take your time and even file the ends, you can make it look like factory.

[@rukus13]

You can also use used mig welding liners for the cables. I’ve used them on push mowers for throttle control. I also made a steel mold similar to making sinkers and melted lead.

[@rickybailey7123]

This was something I never new how many times as a younger man I could have used this thank u I will never forget this no more wating on orderd cables from the Honda shops or Amazon now days use to be Honda!! To be Exact, was a 1985 200x 3 wheeler clutch cable I broke first gear out because I broke the clutch cable and would rev and stomp in first gear to get moving good times great Oldies

[@cloeducationtv]

Thanks for this, Im working on an old 80s Isuzu Truck and I need to make a brand new one of these.

[@ThatHondaGuy2]

I’m going to have to try this! I’ve been using an electrical wire in place of my weed trimmer’s throttle cable, for long enough!

[@slickmouf879]

So helpful thanks man from a boater with a throttle cable problem from South Carolina

[@christianheidt5733]

That's bloody brilliant!!!

[@2000jago]

Instant thumbs up for that cool dog!

[@jaysaw8151]

O lord lol I had a ragged out Suzuki quad runners same engine ..20 years ago ..yours is alot better shape than what I had

[@ligmuhnugs]

Very cool and simple technique. This would work great for bicycle brake cables with weird double ends.

[@sixtyfiveford]

Absolutely

[@mudgyver5205]

I had a notion but never thought about solder. I was thinking along the lines of just melting lead. As a kid I’d make a mold in the ground melt lead to make things but your cable end hack makes it a new ball game. Thanks as always for sharing. 🙂👍

[@boltonky]

Done this more than i like to say especially since we now have no real motorbike/ATV shops in town, we have a honda/stihl shop and even tho there aftermarket parts supplier has all the parts available its like the most impossible thing in the world when you ask exactly what you want. Great video and i am sure heaps of people have used this method (as i never thought about wood, always had mini molds or done it the hard way haha)

[@keithhampton9700]

We used to make our cable ends by drilling a hole in a piece of wood than drill a smaller hole in the side of hole and torch melting old tire waits with cable inserted. Grind to fit.

[@mymorristribe]

As usual, you have the absolute best techniques to fix things. I'd love to see a collaboration with The Project Farm.

[@sixtyfiveford]

That would be cool!

[@ojaichuck]

Exactly what I was looking for. Thank you.

[@sixtyfiveford]

Great to hear!

[@malcolmyoung7866]

Pretty neat little fix. 👍🏻👍🏻

[@DamonBlock-o4n]

Awesome video. Thank you.

[@KonKrom]

This is the content i am here for :D

[@f.k.burnham8491]

Thank you for this video. If only I had known this trick 60 years ago.

[@a77mighty666]

excellent video, will defo be using this to make cables in the future!

[@zadelyne1623]

Wow. That’s awesome, that is very useful! Thanks for the video.

[@whathappened2230]

This will do me good for working on mowers. Thank you Sir!

[@tanksoldier9770]

Great rebuild for a moment there l had thoughts of getting a tooth filled ha ha thanks again

[@richardross7219]

I went to a swap meet on Saturday. They had a raffle to win a 1965 Mustang. I chuckled because I wondered what you would think of it. I am highly suspicious of all modern "restorations" because I have seen some very bad ones with a nice paint job. Nice video. Good Luck, Rick

[@duotronic6451]

Great DIY. Cables cost a small fortune these days.

[@petedude2lu3]

this is the most useful shpw i have ever seen about ctrl cable. it's such a hassle to spec and order cable. thanx

[@kenworks6068]

Excellent, I've needed this trick for years. Now I can do it - Thank You

[@Phantom-mk4kp]

Ginger is a true petrol head

[@sixtyfiveford]

So true

[@wieland12]

Oh I am so going to try this before I spend $50 bucks for a new cable. Thank you.

[@craigsudman4556]

New subscriber, I've watched a number of your videos and realized that your content is aligned with my interests. Great video thumbs up

[@JosuePineda-lz7jd]

Did take me 5 times...6 was a charm...you are owesom ,thank you

[@dcrog69]

Thank you

[@norain31]

i watched a bunch of your vids .you are a genius . i have 3 blue heelers they are a handful. lolo

[@sixtyfiveford]

3 of these wild beasts... Love it. Thanks!

[@tedbastwock3810]

Nicely done, great approach, thanks for sharing it with us.

[@konstantinusstoyanov9749]

Yeah right what feral works on such pressure, good job, thanks

[@NTK_FabWorks]

“I’m going to pack my little hole with some flux…” Yup, nearing 38 years old and still giggled at that.

[@ifell3]

A truly life saving video!!

[@Freeagent-4-life]

I love it, I'm shedding a tear for all of the money you could have saved me over the years.

[@bbbk53]

Very important note when buying at bicycle store. Bike brake cables are thick Bike shifter cables are thinner and more flexible- those are better suited for a carburetor throttle cables.

[@ourkid2000]

Cool video! Any thoughts on how to make a replacement cable that has the solid metal rod inside the sheath rather than the stranded style? Like GM heater control cables.

[@sixtyfiveford]

You can buy the brand new solid wire. It's spring steel, also known as music or piano wire. Most of these cables should be around 1.5 1.6 mm/ 0.0625". You usually bend them with some vise grips or if they're complicated like a spiral round, you can heat them up and wrap them around a screwdriver shank.

[@ourkid2000]

@@sixtyfiveford how cool is that! Great ideas! Thanks again

[@howder1951]

I have made these out of brass, but the solder method removes a single step. Enjoy your tips always, thanks for the video, cheers!

[@robertmailhos8159]

I never seen this one being made at home but it is not a bad idea to do that instead of trying to find a cable for the compression release on a 4 wheeler

[@dethmaul]

So creative!

[@RepairNReport]

i always wondered if solder would work for this. awesome video

[@sixtyfiveford]

Glad you liked it!

[@RepairNReport]

@@sixtyfiveford update. Tried today and failed miserably 🤣

[@DougAskin]

Cool way to form the knob thingy, wood burnt a little but it still formed the way you wanted it

[@napleswolverine7189]

Puppy wants to go for a ride to cool bro. Thank you for the information.✍🏻👍🏻

[@WvMnts]

Thanks

[@fordx4n]

I won't forget this video!

[@zhaosteve9665]

There are knarps available on eaby, you just need a proper sized cable and 2 right shape knarps to get the job done.

[@ranger175a2w]

Good show Moe.

[@sixtyfiveford]

Thanks man

[@Guishan_Lingyou]

That was stronger than I would have thought. Could definitely come in handy. I would have tried finding a piece of brass or steel of the right shape and then drilling it, and then silver soldering. Your way is simpler.

[@c4r5on88]

Absolutely brilliant. Love it bud great work 👍

[@plupyduplupydu1369]

Very very awesome-tried it with an aluminum mold but thay never realy held-thanks man-seeya

[@asianmikedesigns]

use fishing lead weights for cable ends or pop the stem out of an unused rivet, then crimp it.

[@johnvanderburgh4502]

Thank-you especially for the testing procedure

[@FilmForger]

Great idea! Thanks! My Dog used to growl every time I picked him up too... a pride thing - Ha.... cheers!

[@foch3]

In a pinch you can cut the sheathing with pliers if you leave cable sticking out.

[@ranger175a2w]

I didn't find that other video link in the description.

[@sixtyfiveford]

kzbin.info/www/bejne/lauwZIlmq5Z4gLs

[@therealbarnekkid]

Thanks for the infor, much appreciated.

[@byronwoolfrey1039]

Nice video, just an idea, i use old lead tire weights. Stronger.

[@manicmatt7773]

Wicked method love it.

[@stormmountain2521]

Wow. Wow. Good to know thank you.

[@davidf.8497]

Genius! Thanks!

[@joegutierrez2019]

Very interesting I would have not even thought about that. Good to think out of the box 📦 😅😅

[@Hotdaddy536]

Had to do this on a clutch cable on a mercury capri on a sunday .. parts house didn't have one it was a dealer item..well it worked and lasted longer than the car..i see Ginger was ready for a ride..sweet dog..is she a corgi ?

[@sixtyfiveford]

Awesome. She's a Red Heeler aka Australian cattle dog

[@nitrous07me]

This guy is a Dawm genius

[@poolmotorrepairguyFL]

The Florida pool pump motor repair guy 32750 approved ! that was good info sixyfiveford

[@mohamedahmed-th2xr]

إنها طريقة رائعة جداً . أنت الأفضل

[@427v8]

I do the same, but I cut a slot then run the cable past the 'ferrel' then cut off the excess. that way you know the cable went all the way through

[@trentw4122]

8:02 …was quite the Deliverance.

[@idecidenotyou]

@11:06 I became an instant subscriber for life.