Help: Solder throttle and brake cable.

breath_easy13

Active Member
Aug 27, 2019
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Issue 1. Throttle cable is too long.
Issue 2. Brake cable end is too small.

I have two different problems here that reside around the same solution. That being, - how to solder properly. I've watched several youtube videos with people fixing, altering throttle cables using a heat source, and some sort of mold to dip the cable end into.

What i have
-flux on the way (thanks amazon prime)
-solder kit - (from a learn electronics kit) thanks again amazon
-a few throttle cables, diff size ends from messing up so many times.
-solder

Any way, I started by first heating up the gun, 90 seconds, made sure it was hot, thread the cable through the nub, frayed the cable wires a bit like everyone says on youtube, then proceeded to dap a bit of solder on the tip, then tried to simply solder a silver blob into the end of the nub with the cable in place. The blob just flows around the rod, until i add enough solder to it that im able to drop a dab or silver solder onto the cable but instead of filling in the crease of the cable and nub , the blob just plops on top, hardness, untill i reheat it to remove it. NOTHING i do, allows the solder to seep into the crease and mold with the cable.

What should i do, what advice would you have besides using a mold cup to dip the nub into.
 
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PeteMcP

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Wait till you have the right tools for the job. You say your flux is on the way from Amazon. You'll need to apply flux to any joint before being able to successfully solder anything. Even so called flux cored solder wire won't flow into any joint as well as it will after the addition of liquid or paste flux. Any video you watched should have made that clear.
I've done soldering clinics at shows using Coca Cola as flux just to catch folks interest. Not suggesting you use this method. :)
 

breath_easy13

Active Member
Aug 27, 2019
102
30
28
26
North Caronlina
Wait till you have the right tools for the job. You say your flux is on the way from Amazon. You'll need to apply flux to any joint before being able to successfully solder anything. Even so called flux cored solder wire won't flow into any joint as well as it will after the addition of liquid or paste flux. Any video you watched should have made that clear.
I've done soldering clinics at shows using Coca Cola as flux just to catch folks interest. Not suggesting you use this method. :)
Alright, i guess i should have learned that valuable lesson in building motorized bikes that patience is a virtue rather then tryin to hack it.
So when the flux arrives, could you tell me the successful steps to soldering ? From what i understand, i drill the hole for the cable, spread flux on the cable end, heat the cable and with the gun, thread it through, then apply some solder to the rod, then dap solder over the end, and the flux should allow the solder to melt into the hole rather then bubble over ?
 
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PeteMcP

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Basically, flux - together with the application of heat from an iron or torch - is used to provide clean, oxidization-free metal, onto which solder will adhere. Anyone trying to apply solder to tarnished metal will just end up chasing a molten bead of solder over the work piece, rather like a ball of mercury.
From your description, you seem to have the soldering process down - but I'm wondering why you say you have to drill any hole? Most nipples come pre-drilled and countersunk.
For future reference, you might want to opt for solderless nipples which simply incorporate a grub screw to secure the cable.
 
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breath_easy13

Active Member
Aug 27, 2019
102
30
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26
North Caronlina
Basically, flux - together with the application of heat from an iron or torch - is used to provide clean, oxidization-free metal, onto which solder will adhere. Anyone trying to apply solder to tarnished metal will just end up chasing a molten bead of solder over the work piece, rather like a ball of mercury.
From your description, you seem to have the soldering process down - but I'm wondering why you say you have to drill any hole? Most nipples come pre-drilled and countersunk.
For future reference, you might want to opt for solderless nipples which simply incorporate a grub screw to secure the cable.
So i in regards to the throttle cabel, its too long, so i have to cut it, so the "nipple" is already threaded with a cable, so i snip that nipple, then drill a hole through it to thread the new cable length. the issue with the brake cable is that the nipple is too small in that it slips through the brake lever, i have a larger nipple from another cable so i snipped that one, drilled a hole and plan on doing the same thing.. so your saying the flux should allow the solder to easily adhere and "seep" into the new hole solidafying the cable ?
 
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PeteMcP

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Yup. That's the solderless nipples I mentioned in post #4 of this thread.
Adding the art of soldering to anyone's arsenal of skills is worthwhile - but solderless nipples are an easy option. Keep a range of these in your spares kit.