Fabricate a bird cage tool for making motorcycle cables

[@atcmadness4351]

That was the best birdcage video I've seen thus far, well explained... I'd like to see a video on you soldering them up, shaping them.

[@montana2strokeracer]

Thank you my friend, check out such video. kzbin.info/www/bejne/aXjXqpxuZd9sp8U

[@larryb4122]

Hi Dale, A super big thanks to you for teaching and sharing the information on cable building and the bird cage tool. I have failed so many times I'm embarrassed to count them. I found this video and my custom cables are perfect! I built the tool from scraps I had and far less sofisticated tools. I can't thank you enough. Please continue to share your knowledge and experience to educate us.

[@montana2strokeracer]

Awesome Larry, glad you are successful in making your cables now. I too suffered making cables for years, even at the dealership I worked at. All we did was fray the ends to be soldered, many times the ends would pull off and we just ended up buying a new cable. I have found by putting the bird nest on the end I know my cables or repairs are as good as the manufacturer's. I never worry if they will hold now.

[@larryb4122]

@@montana2strokeracer every little thing we fix or tinker with seems to show us how much we take for granted. I never thought twice about cables until I realized how important they were in most everything I work on. Especially vintage machines that you simply can not buy a NOS replacement. Thanks Again Dale!

[@903Z1]

You Sir are a lifesaver can't thank you enough for the video and all the information on cables and every thing else . Nice shop Thanks again Great Video on the birdcage !

[@montana2strokeracer]

Thank you, glad to help, hope you can get your cables made and back on the road or trail.

[@derekshipley-o4k]

Thank you Dale. Funnily enough i was looking to make a custom clutch cable for Triumph and during my headscratching, found Venhill selling the Bird Cage tool. I thought as you did, that's got to be easy to make. I can advise that their price is equivalent to approx 190 USD!!!... So thank you so much for a great video and saving many of us a lot of money. 😊

[@montana2strokeracer]

Holy smokes, 190 USD, that is insane. I sure have had a lot of offers to buy the one I made, I really don't understand why, they are easy to make.

[@peteetwell826]

Awesome video and thanks for showing us how to make a very useful tool. I don't have the need to make my own cables but really appreciate seeing how it is done. Always great to make something rather than to purchase it!

[@montana2strokeracer]

Thanks Pete

[@petermckee1061]

Thanks Dale. Beautifully done, as always. Cheers, Peter.

[@montana2strokeracer]

Thanks Peter

[@torymartinez2439]

Valued information. Thank you for helping so many of us . Its not rocketry but you've certainly put all the eggs in the basket

[@montana2strokeracer]

Thank you, it's a nice little tool to make if you're making many cables. Thanks for watching.

[@alanhoughton3252]

Also in the UK Johnsons Cables have everything for cable making.The Venhill tool is big bucks, I made a similar tool 15 years ago and added a hinge on one end, so it's easier to line up. Also I use plumbers solder rather than electrical solder, I reckon it will be stronger when fixing the nipples on. Oh and don't over heat the cables if using a flame ETC.

[@DavidM2002]

Interesting comment on the plumbers solder. I recall from my high school shop days 50+ years ago that there is rosin core solder which IIRC is for electrical stuff and acid cord solder for other general repairs. I suspect that you used the acid core solder.

[@niconine268]

Yea they taking the pi$$ like

[@beakittelscherz5419]

Awesome! exactly what I need right now. I have 4 Mobylette (Motobecane) to deal with... all with worn out brakes and stuff! Great workshop you have there.Much to learn from you and well presented.Thank you Sir and Greetings from Germany/CarpenterBea🤓😎

[@montana2strokeracer]

Thanks again my friend, sounds like you are staying busy working on your bikes, it's a lot of fun, I think. Thank you I have been working on my workshop for a long time. Now I get to enjoy it.

[@bcp9516]

That is a cool tool. Thanks for the video Dale.

[@montana2strokeracer]

Thank you and your welcome

[@richard-cf8ce]

Thank you for spreading your WISDOM 🙏

[@montana2strokeracer]

Thank you, Richard, hope this tool will be useful for you. It really makes a big difference in the reliability of the cable build.

[@chrisstephens6673]

Great idea, so great i put up a video about 4 years ago on my channel showing such a tool.😊😊😊😊😊 Thirty odd years ago when i was in the bike trade in London we used to make cables for old british bikes and one of our chaps made a single size one and i "improved" the design to do all size cable inners when a friend wanted one. Mine does have alignment pins but as you have replied elsewhere they are nice but not strictly necessary.

[@montana2strokeracer]

Sorry didn't mean to step on your toes. I just saw a picture of the one Venhill sells and thought man I can do that and save some cash. I have had several folks make them and said they used alignment pins also. It sure makes the process of making cables easier.

[@chrisstephens6673]

@@montana2strokeracer not at all, only poking fun. Take a look at mine, no charge😄

[@maitajack]

Very clever. I will start with a small centre drill. Very nice, very clean shop. Many thanks and Merry Christmas.

[@montana2strokeracer]

Thank you, it works very well, I make lots of cables. Merry Christmas my friend.

[@Anotherflyonmyvisor]

Fantastic - Here in England, Venhill a major cable supplier charges a fortune for their birdcaging kit. $180 dollars plus postage. I am going to try and make my own as your video has given me the confidence to do so. Thank You, from Cambridgeshire England

[@montana2strokeracer]

Thanks Dave just went over and looked at your channel and subscribed. I had not run into your work up to now. Yes, that birdcage tool has become my most watched video. I had no idea that so many built their own cables. That is something I do just about weekly around here. I was in need of one myself and saw how much they were and just decided to make my own. It works perfect, you will be glad you did it. Keep in touch, I watch a lot of you guys over in England and in Australia......hard core bikers I must say.

[@Anotherflyonmyvisor]

@@montana2strokeracer well our temperatures are low matey, today I took a sunset ride in 7 degrees centigrade. With the windchill at 69mph it was cold. Ride safe my friend. You’re blessed with a great workshop !!

[@montana2strokeracer]

Not very warm here either, getting some spring snow tonight. But on the nice days you just have to get out there. Thanks buddy

[@photon393]

Have you tried reverse the order of drill operations, if you do the 1/4" first it will leave a nice centered starting spot for the tiny drill. And lessen the amount of material you need to drill through with the wire size bits. Thanks for the great info on cable building, I'm looking forward to getting kitted up with parts to build my own now!

[@montana2strokeracer]

Thats a very good idea, did not think of it. Hope I don't have to make any more though. LOL Thats great it's kind of a rewarding job. Get to building some cables.

[@retromechanicalengineer]

Venhill sell the birdcage tool here in the UK for over £100 so the Sweger Special gets my vote! I get my loose cable inner and outer from them. Best wishes, Dean.

[@jamessharp9790]

Venhill. Sells some quality cables

[@retromechanicalengineer]

@@jamessharp9790 yes indeed, and will make a cable to the customer's specification if they do not have the facilities.

[@fernacticus]

I live in the UK and I use Venhill. They supply all the parts individually or as a kit and also supply teflon liners. I’ve made my own cables since the 70s, which gives an indication of my vintage.

[@montana2strokeracer]

Hi my friend, I to have been making cables since then, when I worked in a Suzuki shop then, we made many cables a week. These days you can't even find bulk cable in our local shop. It used to be a service we provided.

[@fraydnot]

Very informative video, keep up the good work. Looked up the tool it's called cable inner wire bird cage tool $185 in the US. Thanks for the upload

[@montana2strokeracer]

Thank you, yes, I could not believe the price for them, only took an hour to make, works very well, use it at least weekly here in the shop.

[@fraydnot]

@@montana2strokeracer I was thinking (oh boy we're in trouble), would it be helpful to weld guide pins on each end of the plates to allow for quicker alignment? Just a thought. Thanks again

[@ThomasELeClair]

,,,,,,,,,You assembled a fine personal machine shop ; mine is smaller and less equipped .....Good to find a master gearhead's workshop and channel.......thanks.....

[@montana2strokeracer]

Hey Thomas, thanks for the kind words my friend. I just enjoy piddling around with mechanical things. I really enjoy the vintage bikes and the machine work. I am just sure you are in the same boat. Welcome aboard and enjoy your machine shop.

[@chuckvoss9344]

Excellent detail. Thank you for sharing.

[@montana2strokeracer]

My pleasure!

[@zacharykallinen9838]

This is very helpful. I wasn't looking for this, but i actually needed to learn how to do this for my kawasaki. You could use a layer or 2 of masking tape instead of paper as the spacer.

[@montana2strokeracer]

Nice, a lot of cables are no longer available. I make cables at least once a week. Good to have the components and tools on hand to fix your own stuff

[@johnnysgarageTX]

Nice instructional video. Have you considered doing a shop tour? I'd love to see all your tools and machines you use.

[@montana2strokeracer]

Hi Johnny, I have had several requests, I have always steered away from them to me it just seems like bragging, I'm just not that way. Most of the equipment I have is used throughout my videos. Thank you for spending time with me in the shop.

[@wayneknodel3347]

Great information, Thanks for sharing your knowledge, it is really helpful for those of us with a shop full of decayed old "treasures"!

[@montana2strokeracer]

Well thanks Wayne, got some of those decayed old treasures myself. Just enjoy playing with them.

[@markcdeyoung3118]

That is some good information Dale Thanks

[@montana2strokeracer]

Thanks Mark

[@jameslu1588]

Sir i like so much your shop... lots of stuff and lots of knowledge you share... god bless sir

[@montana2strokeracer]

Thank you, James, I have been building my shop for many years, I am really enjoying working in it in my retirement. Glad to have you spending time in the shop with me. You are so welcome.

[@johnvreede832]

If you only have a handheld drill to drill the angle iron, you can still do it by marking out accurately on both sides of the angle iron and filing a groove in each half. A 3/8" (10mm) across flats triangular file will create a half circle groove in each piece. Make the groove smaller than the inner cable diameter (it really only needs to be bigger than the chisel point on the drill). Then when you clamp both pieces of angle iron together in the vice (with the piece of paper or 2 in between since that's what provides the clamping!), the 2 grooves will form a hole that even the smallest drill will run down accurately and true, even if the drill is handheld. The bigger 'cage forming' drill will always follow the smaller hole no matter what drill type you use. If you have trouble making Dales birds-nest punch, get a carpenters brad punch (the type with a cup on the end for the brad head), its what I've used for years as I form the birds nest directly in the brass ferrule (but I will be making one of Dale's punches tomorrow - thanks Dale!) - jv

[@gigicocreates]

Thanks so much for going into detail on the cable tool Dale. Made a note on the kit and cable suppliers here in OZ. I'm thinking my Yamaha AS1 will probably need the smaller cable. I think it's very close to the YL2.

[@montana2strokeracer]

Thanks, Gi Gi, Ah so you're working on a AS1, I actually have a AS1C that I will be bringing into the shop soon. It's the high pipe street scrambler version. Your cables will probably be 1.5mm for throttle, and 2mm for brake and clutch.

[@gigicocreates]

Too Cool @@montana2strokeracer ! Looking forward to seeing the series on the AS1C. I actually prefer the look of that one to the AS1. Was thinking of seeing if I can change the forks to the AS1C rubber boot style instead. Hope you had a good visit with your Aussie friends.

[@hemibreath]

Wonderful information. Unobtanium all the way ! Thanks for sharing your years of expertise and trade expertise 👍

[@montana2strokeracer]

Thank you very much, I am always glad to hear that I may have helped in some way. I am just having a lot of fun doing these videos. Hope you will continue to stop by and see what is going on in the shop.

[@wallyarent6548]

Thank you Dale Once again. Good stuff

[@montana2strokeracer]

Thanks Wally sure appreciate you stopping by.

[@garyisabelle8078]

Seems to work great. Couple suggestions for better accuracy. Install two alignment pins before drilling cable holes. Always use a center drill before drilling. And to avoid breaking tiny drills, use new ones and increase your spindle speed for those tiny drills.

[@montana2strokeracer]

Hey Gary, all good points my friend. Really kind of not wanting to build another one. But all good suggestions that will flow over into other projects too. Thanks Gary.

[@garyisabelle8078]

@montana2strokeracer I'm firm believer in "if it works don't fix it"

[@markaddy53]

great job dale and pretty easy to make the company u mentioned in uk want 160 english pounds four the tool with a couple off mandrells bit steep when u consider the cost off the raw materials used keep up the good work

[@montana2strokeracer]

I thought I saw that on their website, but didn't remember the cost. Guess I should go into the tool making business, LOL

[@thomass2055]

Awesome video good knowledge to have !!

[@montana2strokeracer]

Thank you, thanks for watching

[@luismelero6198]

Very interesting. Hello from Spain Dale !

[@montana2strokeracer]

Well hello Luis, glad to see you spending some time with me in the shop. Thank you!

[@peterdrury5627]

Lovely tutorial. Thankyou!

[@montana2strokeracer]

Thank you, Peter, I never knew there were so many that built their own cables. This has been my most viewed video to date.

[@vincentricher9038]

Hey Dale I know why you made your own Venhill want £160 for that same thing . Another great tuition from you thanks

[@montana2strokeracer]

Wow that is insane, couple other folks have said they are expensive too. Well worth a couple hours work.

[@Rev22-21]

Those 1.25 remind me of what lawn mower & equipment might use.😊

[@montana2strokeracer]

Lot of go karts use them, and even some of the smaller bikes and mini's

[@tonypike5785]

When drilling the small holes the rpm’s on the drill or mill need to be much higher, thanks for the video.

[@JohnnieBravo1]

Hey Dale; just a quick question based on your knowledge and experiences: do you think there would be any advantage to facing off the two surfaces, like with a fly cutter, or facing mill, then put them together and drill a couple guide pins?? Or when you press the cable in the grooves they sort of "self align" when clamping them?? Awesome video! I have to make cables for my (and neighbor's) lawn mowers, as apparently they are getting hard to source any more. (Seems everybody is discontinuing support and parts for gas powered equipment in favor of the new EV stuff). I plan to keep repairing things long as I can, so having these kinds of tools is very helpful.

[@montana2strokeracer]

Hey Johnnie, sure that would be a great idea, it sure would look nicer, but not really necessary, the cables fit perfect if you drill with the proper size bit. By putting the piece of paper between them when you drill, gives it just the proper clamping pressure when tightened up. I have been hearing that the parts are drying up for lawn power equipment. I sure build a lot of cables here, have done some on the mowers also.

[@toddwheeler1526]

Amen sir. Back to the old ways and days of not pilling stuff up in the landfills.

[@wrench17]

Very informative thank you. Honest question, why not drill the ¼ first and then the smaller bits? Then the smaller bits don't have to drill through so much steel.

[@montana2strokeracer]

You sure could do it.

[@captainedc]

If I remember correctly that ASUZA company in California is the same company that made the ALLOY wheels for go carts.

[@montana2strokeracer]

Right on, I used them for go kart parts in the past, the small cable is hard to find, but they have it on the shelf.

[@cainbeeping8480]

Good job brother.

[@montana2strokeracer]

Thanks Cain

[@c2hh571]

Do you have a Vedio showing the cable being made? I looked through your library, did not see. How is the solder use?

[@montana2strokeracer]

Several...here is one kzbin.info/www/bejne/aXjXqpxuZd9sp8U

[@donbridgewater2988]

Hey Dale👋 I was wondering about this.

[@Mohenenvy]

Hi sir, it was an elaborate n informative vid to me, here in India. But.. am not sure if I could find the resources so easily as you do in your country. Anyway, being a tech savvy guy, enjoyed going thru your vid. Thank you v much, n God bless.

[@montana2strokeracer]

Thank you sir, glad you enjoyed it.

[@dralexmclean]

Dale: Thanks for the video! I was wondering what diameter holes you had drilled to clamp the wires. I'd looked at that Venhill unit a few years back but it's bloody expensive and as you said pretty simple. I just couldn't figure out how to drill the holes just the right size - I never thought of the spacer between the angle Iron pieces - Brilliant!! I also like that you used a drill bit rather than end-mill to make space for the rod that makes the birdcage as the conical shape will help form the birdcage better than a flat bottom would have. Venhill seem to have bulk cable and outer housing listed but Motion Pro don't seem to have it anymore. Thanks so much for making the effort to post these videos, I know they eat a LOT of time.

[@montana2strokeracer]

Hey Alex, I drill the holes in this case 1.25mm, 1.5mm, 2mm, and 2.5mm the same size of the inner cable. Yes, the drill bit is the only way to get the birdcage shape. I just looked on Motion pro's site and I see all that cable...inner and outer in stock and ready to ship. Let me give you some part numbers to plug in over at Motion Pro. 70-1100, 70-1104, 70-1101, 70-1105, 70-1102, 70-1103. Let me know if you can't find them. You're welcome, I appreciate you taking the time to watch.

[@dralexmclean]

@@montana2strokeracer Thanks much Dale, I'll look 'em up. That said where I live I order everything so Britain is not really any more difficult than the US except when you want to actually talk to a person (8 to 9 hr time difference). Motion pro is easier no question as my local Suzuki shop guys bring stuff in and give me great prices on Motion Pro stuff and no shipping costs! Going to make up a Bird cage jig, thanks for providing the motivation! Thanks again Alex

[@juannunez1566]

Thank you for the video, where do you get the solid wire soldering 60/40?

[@montana2strokeracer]

I buy it by the bar on Ebay, just search for solder bar 60/40 it should come up, seams it comes from Washington State.

[@1crazypj]

Dime City Cycles in Florida (Tampa) (I hadn't watched entire video when I posted that) 1.25mm was common for choke cables on 1980's Honda's and Suzuki's Being 'crazy' I make nipples when I need them, usually just making throttle cables though and using bicycle outer's as they are available in various colours. Red on Honda's (and Maico 😁), Yellow on Suzuki's I've got some Blue for Yamaha's but haven't started playing with them again yet. I don't generally do Kawasaki's but green is available (various shades last time I looked) It's easier to just clamp the paper in place and use a razor blade to trim off top. Oh, to anyone making cables, make sure to put the nipple on first or you'll be cutting end off and starting over sometimes from the very beginning if the inner end up too short for outer I've seen people forget the outer sheath, ferrules, adjusters, etc. I've always seen it called bird nest

[@montana2strokeracer]

Wow sounds like you have some experience at this. I have to say I have forgot all the above before, you just have to go back and fix it. Thanks buddy.

[@jerrybigrig9475]

Shadetreesurgen used to go there ..👍😎👍

[@bdento59]

Have you made these tools for folks like me that don’t have milling machines or properly accessorized drill presses?

[@montana2strokeracer]

No, I just made a video on how I made mine. There was a guy on Ebay making them from my video and selling them, or you can order from Venhillusa.com but hold on to your wallet they want 185.00 for theirs.

[@romandybala]

Great video. How do you make the brake lever ends? The little barrel ones. Thanks.

[@montana2strokeracer]

Here is a video were I made a cable. I buy the cable ends from Motion Pro. kzbin.info/www/bejne/aXjXqpxuZd9sp8U

[@the1khronohs40]

Excellent!

[@michaelsimpson9779]

Nice work

[@montana2strokeracer]

Thanks Michael, this is a great little tool, use it every week.

[@Mohenenvy]

Hi again, wonder why the cable head filling part was left out.. it would hv bn helpful how you went about it.

[@montana2strokeracer]

I didn't make the cable ends; they are premade and just soldered to the cable.

[@Corey-dy2cq]

Hey Dale good as always. Can you tell us what your favorite metal bits are? Maybe give us a link? Thanks!

[@montana2strokeracer]

Hey Corey, I get all my drill bits from Grainger, my favorite bits are Cle-line made in USA, not the cheapest, but last me a long time, I also sharpen my own if they are over 1/8 inch. 1/8 and below I just buy new ones. www.grainger.com/

[@TheWilber09]

I'd think an endmill would be ideal for that to get them started, at least if a guy has the ability. Could get crazy with that and mill the faces and that would look really nice and "store bought"

[@montana2strokeracer]

The drill bit gives it a taper above and below for the creation of the birdcage. If you used a end mill the cage would be flat top and bottom. Maybe Im not understanding where to use the end mill. But yes your right, milling the faces would sure make it pretty.

[@dralexmclean]

Use of a drill rather than an end mill has some advantages as the hole at the bottom is cone shaped not flat when made with a drill. You're trying to contain the wire so to speak as it mushrooms into the "birdsnest" and the combo of the cone at the bottom and the cone in the end of the punch do a great job of that.

[@holmes1956O]

Wow I am 67yrs old. I have been riding racing and wrenching on motorcycles since I was 13yrs old and have never had to do or use anything like this to put an end on a cable. All I do is put the brass end on the cable grab the cable with 2 pair of pliers and slightly fray the end pull the brass end up on to the frayed part solder it in place and clean it up with a file. Nothing special required. Using my method with a small butane torch you can fix a cable in the field

[@montana2strokeracer]

I know me too, when I was working in a bike shop in the 60s and 70s that is all we did, fray the end and solder. I find myself these days making many cables, I saw this tool listed in England for over 100 dollars US. I thought this would be easy to make, so I did, it has been an extremely popular video. I find it works very well and I use it several times a week. Thanks for spending time in the shop with me.

[@billjacobs386]

Nice, thanks

[@montana2strokeracer]

Thanks Bill!

[@bicifamily]

Can u use this tool as a mold as well If so how do i make the solder to not stick to the angle iron? Maybe u have a trick for it Thanks

[@montana2strokeracer]

No, it's really not the right size for that, not sure how you could do it without it messing up the tool. I just mold some of the nonstandard size ends.

[@bicifamily]

@@montana2strokeracer i figure it out thanks much it works great

[@bee2333]

What flux and solder wire?

[@montana2strokeracer]

Answered this in your other comment on the video making cables.

[@orlandooquita69]

Do you sell them already made ?

[@montana2strokeracer]

I'm sorry I don't. This was just a DIY video. You can buy them from Venhill, think they are about 165.00 plus shipping.

[@jamestregler1584]

Cool thanks

[@montana2strokeracer]

Thanks for stopping by James, I appreciate it.

[@2000jago]

I'm in Thailand, who do I try for these pieces?

[@montana2strokeracer]

I think you are asking what or where to get the metal. This is called angle iron and is available at a steel supplier or a hardware store here. Not sure about Thailand.

[@n.b.p.davenport7066]

Make master car or Grainger they should have everything you might need

[@montana2strokeracer]

You bet, got my drill bits from Grainger. They are a good source.

[@frankdillon6127]

quick draw Cain he is called. do i get anything for 4th place? LOL

[@montana2strokeracer]

Frank the slow poke

[@retromechanicalengineer]

Here!

[@trialetcompagnie4481]

👌👌👌🔥🤙

[@montana2strokeracer]

Thank you

[@robertmccully2792]

I never bought metric drill bits in my life, they did not teach me metric in school.

[@montana2strokeracer]

Yes, I know, it wasn't taught when I was going through school either but got into jap bikes and something you kind of need to know. Not an expert either! I was able to use imperial drill bits for 2 of the millimeter sized cables, but two I couldn't, when you tighten up the tool it would deform the cable, so the next tool I made was made with millimeter size bits and it worked great. Not happy about the millimeter system, but I am afraid it's here to stay.

[@wheater5]

But you need to put the fittings on before birdcaging the other end….

[@montana2strokeracer]

Roger that, I cannot say I have never done that. LOL

[@wheater5]

@@montana2strokeracerSame here!

[@cainbeeping8480]

Here

[@retromechanicalengineer]

You've got to be kidding me Cain! That's fast.

[@danfield977]

Great video - thank you but for god’s sake man, use metric or imperial!

[@montana2strokeracer]

Thanks Dan, I know man, most of the time its straight in my head. Guess I'm just into variety.

[@colinfoote8683]

dont under stand.

[@montana2strokeracer]

I can help, please some specifics.

[@masterwood498]

Can just go to parts store t9 get cable clamps 🥴