Brake cable quality

[Vantage]

The last few times I've fitted a new brake cable, I've noticed that not long after I've tightened the clamp bolt and bent the cable to sit behind the arm that the odd stray strand snaps off.
It's happened again this morning on a new stainless steel Fibrax cable.
Does anyone else get this or is it just me using cheapo cables?

 

[Globalti]

Classic over-tightened bolt, I'm afraid; you have crushed the cable. Will you be cutting the excess off cleanly with cable cutters and fitting an end-cap?

 

[T4tomo]

what exactly do you mean by "bent the cable" - that might also be a contributory factor if its a sharp bend.

 

[smutchin]

You're overtightening the bolt, as @Globalti says.

Also, you don't need that much excess cable. Cut off the end, leaving no more than about 5cm, and fit an end cap. Use good quality cable cutters for this to ensure a neat cut without fraying.

 

[Globalti]

Oh, so you've tried to deal with the excess by bending the end behind the fork? That's not the way to do it; with the stress of crushing by that clamp it's inevitable that one or more strands will snap.

These are expensive but will give you a lifetime of clean cuts of cable inners and outers:

While you're at it, buy a packet of end caps. You crimp them on using the first narrowing just up from the pivot bolt:

 

[ColinJ]

While you're at it, buy a packet of end caps. You crimp them on using the first narrowing just up from the pivot bolt:
View attachment 415005

You can buy a bag of 100 on eBay for a couple of pounds, which is what some bike shops charge for just a few. (They will come on a slow boat from China, but you will never need to buy any again unless you have about 20 bikes or open your own bike shop!)

 

[Globalti]

Ha ha, that's true until you drop the bag and most of the flippin' caps fly out and disappear under a pile of garage junk!

 

[Vantage]

Oh, so you've tried to deal with the excess by bending the end behind the fork? That's not the way to do it; with the stress of crushing by that clamp it's inevitable that one or more strands will snap.

Nooooo Nooooo Nooooo. I trim my cables with a dremel which leaves a nice clean cut and I do use cable end crimps.
I used to tuck the cable behind these little studs

but figured it was the tight radius I was bending the cable that did it so today I opted for a longer cable going in a bigger curve and tucking behind the bosses to relieve stress, but as you and smutchin said, I do have a tendency to strangle the cable to within an inch of its life when it comes to brakes.
I'm thinking a small torque wrench might be in order.
Thanks chaps, as always I appreciate your help

 

[raleighnut]

Nooooo Nooooo Nooooo. I trim my cables with a dremel which leaves a nice clean cut and I do use cable end crimps.
I used to tuck the cable behind these little studs
View attachment 415013
but figured it was the tight radius I was bending the cable that did it so today I opted for a longer cable going in a bigger curve and tucking behind the bosses to relieve stress, but as you and smutchin said, I do have a tendency to strangle the cable to within an inch of its life when it comes to brakes.
I'm thinking a small torque wrench might be in order.
Thanks chaps, as always I appreciate your help

I've always routed the cable behind that little spring stop.

 

[Drago]

Next time you fit a new cable whip off the clamp and carefully bevel the edges.

 

[Crackle]

I tend to take the cable around the curvature of the bolt as well to bring it out at the angle I need, if possible, which it isn't always.

 

[Globalti]

No matter what you do with the cable, if you leave it un-capped it's going to fray and then your bike will look like one of those poxy BSOs that you see outside supermarkets.

 

[rrarider]

I find it hard to believe that a Dremel with its sawing action can give as neat a cable cut as the two closing V shaped jaws of a purpose designed wire cutter. Not all such cutters are as expensive as the one previously mentioned.

 

[Globalti]

My Park Tools cutter is my second; the jaws of the first got spark-eroded when I used it to cut through a mains cable loop that the electrician had left out for me to install a 13A plug. The trouble was, he'd taken the loop off the downstairs ring and I'd turned off the upstairs ring.....

 

[Vantage]

Oh you'd be surprised how clean a cut a dremel cutting disc makes. You have to be careful cutting outer cable though because if cutting for too long, the plastic casing can melt which makes a right mess.