Finishing cable cuts (manually)

[Archie]

I've got some brake and gear cables I need to shorten for the cable installation. I believe the "pro" method is use an angle grinder or similar to get a nice clean square cut, but in the absence of any power tools what's the best method to finish the cable edges after they're cut?

I've got a set of cable cutters, but I get a raggedy edge on the brake cables. It'll be the first time cutting the gear cables! That probably confirms the fact I'm pretty much a novice at this.

 

[mickle]

Are your cable cutters scissor action and if so is the hinge good and tight? Every so often I dismantle mine and dress the business end with a flat file.

 

[RedBike]

Grinders, power tools? Why go to all that trouble when a good set of cutters will do?

With brake cables you're probably going to put a cap on the end anyway.

 

[mickle]

Indeed, no-one in their right mind uses a power tool to cut cables or outers.

 

[hubgearfreak]

Indeed, no-one in their right mind uses a power tool to cut cables or outers.

i've done it, but that doesn't prove you wrong

 

[Archie]

Are your cable cutters scissor action and if so is the hinge good and tight? Every so often I dismantle mine and dress the business end with a flat file.

Yep, they're Shimano (TL-CT10) and the hinge seems pretty tight. It should be, they're practically new!

 

[Archie]

With brake cables you're probably going to put a cap on the end anyway.

True? They're going on Ergo's which don't need end caps, and I've always thought the brake end didn't need one.

 

[mickle]

All cables need caps. Try cutting the cable with a bit of tension on it.

 

[spence]

A good pair of cable cutters (Park etc,) and you'll be fine.

Once cut use an awl or similar to open up the end to round again. I have heard of inserting an old piece of inner cable in the new outer before cutting to keep its shape, tap out the offcut.

 

[Proto]

I use decent side cutters to cut the outer cables, then I tidy up the ends on small bench grinder.

BTW the new Campag Ergos have no cable end caps on either the brake or gear outer casings. Older Ergos used to have caps on the outer gear cables.

 

[Crankarm]

You need a set of sharp cable cutters or even pliers with a good sharp cutting edge in the jaw. Practice first on the cable end by just cutting little bits off. Personally I have a decent pair of electrical wire cutters and crimper. They go through brake and gear cables like butter giving a nice clean cut then pop a cable cap over the cut end and a couple of dinks in it using thin pliers to hold it on. Simples.

 

[RedBike]

I must be missing the point completely. Why do you need the cables / outer perfectly finished when you're putting end caps on them anyway? And why don't your cable cutters cut the outer/cable straight and tidy in the first palce?

 

[jay clock]

I pull taut with pliers then clip off using a very good pair of cutters. The tauter the better. I see the point about why you need to, but if you let them fray it spreads up the cable and if you ever need to adjust them it is a pain....

 

[jpembroke]

If you are concerned then insert the neat, pre-cut end in to the ergo (will help the inner cable enter the housing without any issues). Then cut housing to length with your cable cutters, trim any wayward bits (sometimes brake cable doesn't cut cleanly), re-round the cut end with a awl/braddle and fit an end cap. Pretty easy really.

 

[Mr Pig]

If you don't want to put caps on the cables, for some mad reason, you can solder the ends.