HOW TO SOLDER Throttle & Brake Cables

[@RobertJohnson-ec2uq]

Possibly the best KZbin video ever. Clear, concise, not a single wasted word, straight & to the point.

[@donyboy73]

check out my other videos Robert!

[@MikeNBikes]

This video was posted in 2010, here we are in 2023 and I'm using this video as a reference. Thanks for the straight to the point video

[@davidmccarthy7253]

should be used as a training video for others making training videos. a. no horrible music b. starts off talking about some of the challenges instead of pretending like everything is always easy c. no jumps. all the steps are shown and described (with static downtime nicely removed). really well done. wish i did this search a week ago. or maybe not. every horribly failed disaster is a learning experience i guess.

[@JohnMSawyer]

And no long, interminable opening and closing credits

[@paulbillings1791]

Every failure is a prompt to success. Strive on.

[@finbah5706]

things I learned in this video 1.) cut 45 degree V notches in my vise. great hack I need it too. 2.) How to make my own cable ends. Thanks Donnyboy!

[@dirkmohrmann8960]

Thanks for the instructions, my clutch cable is fixed and working great. I didn't have lead solder or Methyl Hydrate, so I tried it with acetone, and used regular rosin core solder. It worked perfectly.

[@vazquezel1]

I have a 1993 Corvette and my throttle cable broke off the dealer doesn't make the cable anymore and there are no after market suppliers. This video has saved me time and several hundred dollars for the cost of a new cable. Thank you.

[@gregschleitwiler2557]

Yayyyyyy! I was going to take an old hand brake from a bicycle, but now I can put the cable back in the lawnmower handle just like new. Thanks for this.

[@wbgator1]

Don: I bought 50ft. of 1/8" galvanised cable at Princess Auto for $10. I got some old led weights from car wheels. Used your method and I am saving me and my friends a fortune. Also, because the cables are galvanised they are not plastic coated, and will never rust, and the plastic will never crack up or peal off, and the cable fits perfectly into the groove in the little wheels that they go on. THANKS!!!!!!!!!!!!!!!!!

[@jamesrichardson771]

Wow 💥 you never cease to make me amazed at your vast knowledge of genuine common sense !!! Absolutely" love your videos !!!

[@paulkerst7446]

Don, you do a really good job of presenting your information by video! I also appreciate the time and thought you have put into your neat and efficient shop!!! I wish you continued success ! Paul in Pennsylvania

[@donyboy73]

thanks Paul!

[@pauleastend4706]

Excellent tips Danny......ya lead is scarce today.....maybe use old fishing sinkers if you can't find lead.

[@Phillijr100]

PERFECT! and for 2 days I've beat myself over this simple fix

[@ronmartinmhg2804]

Years ago, when into motorbikes in England, when throttle cables broke, the answer was to use a barrel nipple with a screw in the end to grip the cable. They lasted for a while and then you had to buy a new cable. If only I had known this trick! Nice one Donyboy

[@BigAgitator]

Very very helpful! Thanks! I'm a mechanic and this will come in handy many times, especially when dealing with obsolete equipment.

[@mushpaladin4159]

Dude ur the man! Just made a throttle cable 4 my go kart, piece of cake. Hats off to you my friend

[@stevedittrich4411]

Sometimes you need to repair one of these cables TODAY, and can't wait a week or two for a replacement through the mail. This is an excellent technique, quick and easy, to repair such a cable.

[@cmsracing]

At first I could not see where you were going with this till you pulled out the first one, then the light came on! Thanks for sharing!!!

[@donyboy73]

greetings from Canada

[@paulskartslifan4206]

That's kinda what I do ...I use aluminum foil ,shape it by pushing on my finger and leave a handle ..forming a small pot of sorts ..then I cut pieces of solder ,put them into the small aluminum foil pot ..heat it till it melts and dip the cable ....I also have to Frey the ends ...i like your way better since the wood acts like a form..the drillbit idea is genius! I also never cleaned my cable and had success...so I bet doing it your way works out to be perfect...clean ,fluxed,with the wood mold ! Awesome bud ...awesome !

[@darrentylor5473]

Wow... That was old school fabrication. You def learned that from a legend bc no one would even think to take it that far back...its elemental...

[@boonang4097]

Never ever thought I would be able to know how brake cabling is done! Fantastic video. Thank you very much. 🙏

[@ncrdisabled]

WOW in my 55 years I have never see it done like this. Thanks!!!

[@johncaboose8743]

i gotta say, your videos have helped me out more than once. great info and right to the point. fantastic work.

[@HumberNorton]

Great tutorial! I'm going to re-make the front brake cable for my 1955 Matchless motorcycle! Thanks!

[@csb772]

Best soldering how to video on KZbin. I have watched them all and this one helped me the most. Thank you!!!

[@peroduanippa]

Nice video, I've never had much success with soldering, I've seen this method before and gave it a go, I used engine start spray to clean the end of the cable and blew it with compressed air, instead of wood I used a thick roof tile and the solder was running out of the side hole so I packed it with foil. it worked fine, I got a good strong ready shaped end.

[@durenknives]

thanks for the tip, ive watched all your video's and learned how to work on all my stuff because of what ive seen in your vids. Thanks for making me the small engine mechanic i always wanted to be!

[@evanparker]

this is a superlative how-to video. you describe the process incredibly well, thank you for putting this together so nicely. i bet if you had a block of silicone instead of the wood, you could have a reusable block that wouldn't burn that you could use as a mold for the lead!

[@BarryCBrown999]

I first needed (and failed!) to solder a m/cycle clutch cable in 1964. I've never been able to successfully solder any cable since, despite trying many times and using masses of heat and endless solder. So a BIG thank you, donyboy - a great tip for succesfully doing a seemingly impossible task!

[@666mrjimbo]

DONYBOY !! YOUR TALENT ALLWAYS AMAZES ME !! KEEP UP THE GREAT WORK DUDE! IAM SURE OTHERS LIKE ME ARE ALWAYS FINDING YOUR VIDS A GREAT HELP WITH MONEY SAVING IDEAS!! HAVE A BEER ON ME!!

[@tapia62361]

every day we learn something different thanks dony for the lesson

[@donyboy73]

you're welcome, thanks for watching

[@finbargolden5825]

Excellent tip!! I would never have thought that I could repair a cable with this method!! I must commend you on an excellent and professional channel. I will be sharing it with my friends.

[@donyboy73]

thanks!

[@OpaKnows]

Great tip for a DIY fix. Thanks for the info and the well filmed, step by step instructions.

[@idespiseallconartists8943]

Thank you for this info.: I'll be using your method to fix a broken bike brake cable tomorrow! Cheer's👌!

[@donyboy73]

@BigAgitator i learned it from a mechanic myself, very handy like u say for obsolete cables

[@iRaveMuch]

2 weeks ago mine broke.. i was stressing out where i would get one to fit without having to pay heaps for a custom size since my motorcycle is a little older and parts are not exactly streaming around the place. Mate you are a CHAMPION!! i will do this asap and get her back on the road. Thank you for this helpful video =)

[@battlehrfred]

sweeet idea danny. I myself do use general purpose copper tubing,whichever size i need i cut it of a roll, wheather it be a, 1/8,3/16, 5/16 or whatever size i need to make the same sizeknob end. make sure it clean inside of copper tube (i use scotctbrite 3m green scuff pad). drill the same size hole in the one side of copper tube as the same size as the cable itself. Lay this small piece of prefered copper tubing vertically on a wooden table/workbench(hold wit small visegrips if you got a shakey hand). fill it with flux,install your cleaned and prepared cable in through the side of the tubing.Heat tubing until flux bubbles whilst holing cable in hole, fill u copper tubing with solder until its full to the top.Hold steady let it cool. now its a good bushing for movement and wearing charactristics of the copper itself.ty 100-100 vid!!

[@bobbyowen8716]

Prefered method if I can find tubing. I could go out and fix a cable right now with what ive got on the bench, using this casting technique.

[@MattsShop]

This could have saved me a ton of times. Never thought about doing this though. Thanks for the vid!

[@paulm3481]

Just ordered a cable.Will try this next time thanks.

[@ramirythm]

Thank you so much for taking the time to make this video, very informative and clear instructions

[@donyboy73]

it dries very quick and cleans very well

[@jowarr44]

This is so helpful. Thank you Don & Joanne

[@Mi-cha-el-Edward-Lee]

Yea; I am happy to learn this. I am wondering if a mold can be made of something non-flamable; like a metal or something that will not heatsink the work.

[@aoeuidhtnsnthdiueoa]

Wow! This is amazing, I've tried and failed so many times doing this, finally a good method! Thank you.

[@2740142]

thanks so much for this it works great instead of the methyl stuff I used denatured alcohol I was so pissed off yesterday harley davidson wanted $190 for a steel braided throttle cable and I needed it asap for a long trip . I went to a bicycle shop bought a cable for $4 and followed your instructions it came out like factory I even put it in a vise and pulled +yanked to be sure

[@e035830]

This is great! Thank you. Next, I was wondering if you have a method to replace or add the metal ferrules to the ends of the outer covering on the cables?

[@MrAlittle5150]

GREAT video , You do have the best "how to" videos on You Tube. THANKS and keep up the great work.

[@bobherres2649]

Excellent video, Don was always a great teacher, and still is a trusted source of solid information! Thank you

[@georgiowee]

Thank You : may I say You are the king of information ? Best Regards

[@crusin68]

Thanks for the tutorial! I fixed a $60 broken cable with this technique, worked perfect!!! BTW, I used silver solder and flux for doing copper plumbing, seems to be holding up so far.

[@conradsigona]

A brilliant idea. Thanks for spreading it to us poor DIYs.

[@donyboy73]

@canadaeast u may want to practice on another cable first. u can make different molds depending on the tip u need

[@meradu2]

Nice Donyboy I have a 1995 Mercedes gas throttle cable and try very hard to do this and was not working ,this is so good thank you so much Donyboy

[@clintonearlwalker]

Great vid, thanx. I may have to try this in a pinch. One thing that crossed my mind, is instead of wood, maybe drill a piece of steel to get a more accurate shape, maybe cut a little notch to allow the cable to be removed. I don't know if the solder would stick to steel though and prevent it from being removed.

[@tribulation138]

Dony. Did this on a old poulan chainsaw last night. I didn't like the the stock setup of the throttle cable. So I made a more direct route and had to shorten it. Worked awesome. By the way I used carb cleaner to clean the wire and it seemed to work good,

[@miketalbot809]

Thanks Dony. That's great there are some cables that are hard to find. Can't wait to try it out.

[@kylehiggs6439]

very good video, thank you for putting this up my father has a 1980 honda xl250s and as you guessed the throttle cable is impossible to find so im using your method to fix the cable as a surprise for him

[@donyboy73]

good!

[@ngnPhalyr]

Clever. Do you have a mold making method for the crank-like end of cables?

[@davescott8859]

Donyboy, I want to thank you for sharing your knowledge, this video was great stuff to know. Your passion shows through in all your work and then giving all of us help is a wonderful gift. Thank you.

[@leonacndanmark]

hi again mate...i can see there is a ton of Flux on ebay..and i am looking for the paste/cream or grease type like you have, but the big question: should it be some special flux when you are "soldering" lead to steel or just a random one?? Thank you in advance!

[@ChargerMiles007]

Perhaps you could obtain the lead from used tire weights, or fishing sinkers etc., then melt them down for your stock material. Just an idea. Great vid, good to know how to do this, for sure!

[@donyboy73]

+ChargerMiles007 good idea

[@rickasdnorth]

I thought zink was used as tire weight these days.. lead is a bit poisonous ...

[@CVP-og9pw]

Tire weights are made from zinc

[@arnenelson4495]

I use a solder pot I was lucky enuf to inherit- don't know if they are still made but you made a small version of it in the wood. Good job.

[@evanhurtig708]

Great video. I like that. I also saw a similar video and the guy took a core from a Old D cell battery and drilled it like you did in the wood but he drilled the battery core and it does not burn. Interesting. You may like that as well.

[@hsntrkmnturkiye5326]

thank you for the video...I got useful information with your help...a nice work that every human being can do...

[@jadesystem]

Ingenious video. Well done and very practical and unique application for the DIYer. Have seen a few variations on repairing/modifying end cables on KZbin. This is also very good. Thanks donyboy73.

[@tammygosnell]

Great Video .Been wanting to learn my whole life as well.The more you know ,the less you have to buy.

[@donyboy73]

+tammygosnell yes for sure!

[@letsdowater7]

Hi donyboy73. I have watched several of your videos and am extremely impressed at the quality of your work. Your videos are clean, simple, and easy. Thank you for the excellent work. Wayne

[@wbesack]

This is really great information. I'm restoring a few Arctic Cat minibikes and cables for them are unique and hard to find, not to mention ridiculously expensive. On average they go for $25 each. Now I can make them myself from cheap standard $5 cables. THANKS!!!

[@johndeere445]

Im 12, and i cant exactly rebilud an engine, but im definately still learning. I love the videos. Keep em up! Question. The connecting peices on the end of cables for choke amd throttle, the little peice that kind of resembles an s, the ones that connect to the valves, can you sodder those on do u think? How?

[@andrewnichol1658]

Used your system to repair a snowblower cable that is no longer available, thanks very much

[@littletoze]

Very Nice Dony! You could leave the cable in there and solder it on, in place.

[@lionpit13]

GREAT VIDEO , i work on mowers and tillers . that is one of my problems , thanks

[@bobbymorrow3215]

GREAT video!! Will give this a shot. This method will save a LOT of people a LOT of money, and make a LOT of "stealerships" mad!!! THANK YOU!!

[@pattinker1]

just tryed in myself .. on my old skidoo throttle cable works like a brand new one :) ... thanks for the tip donyboy73

[@paulang8267]

Man this is great, I've been wanting to fabricate such for emergency substitution than waiting for parts to arrive. Good of you to share.

[@blairguinea6811]

Nice job Donny number 1

[@enginemodify]

this is really good to know . did the solder stay on after a lot of brake use?

[@jayd1102]

My hat is off to you man well done im going to do this to my throttle cable and you've helped me out a lot

[@donyboy73]

@Autophysn thanks for watching

[@GeraldThomasphotojunkie]

donyboy you are like a mad scientist dude! Great job!

[@GeraldThomasphotojunkie]

donyboy73 I just got done watching it! man you got talent!

[@donyboy73]

@sandydogy it's the same stuff as in gas line antifreeze. u can buy it at the hardware or paint store

[@williambrink7153]

This is awesome. I made a cable last night after learning how to do it from your video. It worked on my 3'rd try. I was using 40% tin 60% lead solder. Does it work better with 100% lead? I was worried that all lead would not be strong enough. Have you ever tried this technique to make a Z bend cable end? I'm going to try it. I'm hoping I can make a long enough end that I can bend it into the z after it's finished. I don't know if it will break or not but I'm going to try. Thanks for this video.

[@lutoveti967]

Lmfao!!! BROOO... you are my lord and savior right now! TY

[@donyboy73]

thanks Wayne, make sure you have subscribed

[@RottnRobbie]

More than a decade old, and yet still a GREAT how-to. Thanks! But I'd be careful putting lead on a grinding wheel. Airborne lead dust demands use of a good particulate mask!

[@donyboy73]

Good tip!

[@pepsijim1951]

great video,,i have learned a lot from donyboy this guy knows his stuff tks

[@donyboy73]

@johndeere445 u would have to make a mould in that shape and then solder the tip and grind it after to fit

[@donyboy73]

thank you sir

[@donyboy73]

@jacquesryan wow, i didn't realize my videos had such an impact, a lot more to come

[@donyboy73]

thanks for subscribing!

[@donyboy73]

thanks Randy

[@vinces8974]

That was brilliant , Thank you for the info

[@pikeywyatt]

excellent,that helps me a lot with my rebuild of my old voskhod 175.thanks

[@lencranston8183]

Great information, Donyboy

[@synchena]

Great video Donny and appreciate your time doing these videos! Hats off to you man! Greetings from Manitoba!

[@mitchlec8916]

Great video! very informative, would it work if I soaked the cable in acetone instead? Also, if I melted the lead before hand and poured it into the hole would that work as well or would it harden to fast buy the time it's poured in? Thank you for any information.

[@patricklogsdon1]

Thank you for this very well done video. I have been wanting to know how this has been done! Regards from a cyclist in Louisville KY.

[@sandydogy]

what is methal hydrate? I am in the UK and sometimes we use different names for things! great video Thanks

[@wbgator1]

Don: if you have a wire wheel on your bench grinder, just hit the end of the cable on that and it will open up the end nicely, BUT I always put the cable through the tiny 1/8" hole first. Just noticed, I have been using FLUX, going to switch over to the methyl hydrate and see if it is better

[@droid740]

I did this with lead and it sheared today. I'm going 50/50 silver/tin and trying it again. Silver/tin takes a long time to cure. Like a minute to harden and you don't want to move it while it dries.