How to repair a cable? Today I will show you perhaps the best way to make cable bosses. This is the best way to make cable bosses. You will be surprised how simple, fast and reliable it is than riveting and soldering. In addition, this method can be used to fill any intermediate or end bosses on bicycles, moto and auto cables.
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The front window regulator on the Toyota Carina E has broken. It turned out that the cable broke on the intermediate boss, which I was repairing a couple of years ago, but in a slightly different way. Then, when soldering, he used acid, because of which I think he rotted. And it could have been done, as now, much easier and better.
Let's replace it entirely. How to repair a cable?
I bought a rope in the construction market. It is worth a penny. Length from boss to boss 185 centimeters. Center boss in the center.
The lugs will be cast from tin this is a life hack. This is the best way to make cable bosses.
Someone will say that it is difficult and timeconsuming, but you will be delighted with how simple it is. The life hack of this method is that we will have a mold for filling from an ordinary wooden block. It will save you a lot of time and hassle.
For the intermediate boss, we will select a drill with the same thickness as the cable. My drill is a little bigger, which is even better for me. Let's drill a through hole. Now we will select a drill according to the diameter of the intermediate boss. The same drill can also be used on end bosses. I'll just drain a little later. Deepen the hole to fit the boss. The intermediate boss mold is now complete. The shape of the end boss is even simpler. It will be slightly smaller. Imagine if I did it from plaster. Gypsum must be mixed, the mold must be dried. And then just a couple of minutes and both forms are ready. First, fill in the extreme boss. I marked the cable with a marker. I cut off the excess. It doesn't matter what kind of wire you make. Window regulator or handbrake, do not forget to put on it what will not fit through the lug. How to repair a cable.
In the factory bosses, the ends of the cables do not push, we will fluff it up a little. It will be safer this way. Next ... Cut off a piece of tin, put it on top. If you don't have a burner, the tin can be melted on the stove and then poured into a mold. I've already made a couple of bosses with a regular burner. And I think even such a small burner will cope with this task. Heated. Insert the cable, kind of chat a little. We will remove the excess with a knife until the tin has cooled down this is also a life hack. If you need to trim, you can heat the tin and it will spread, or trim it with a flat file. A smooth file edge will not damage the cable. Tin is easily removed. The boss can be pulled out by poking it a little with a knife. It turned out to be a very pretty boss. And you must agree such a life hack deserves a like.
I will clean the edges with a petal circle later.
Now let's make an intermediate boss. Many people think it is very difficult.
In fact, I already filled my intermediate boss with my own hands. I filled it in and only then thought that such a video would be useful for you too. Therefore, we will make another intermediate boss on the remaining piece of cable. The cable was passed through the through hole. On the reverse side, it can be bent. We put the tin. Old tin, with slag, slag, in theory, will float up. And again we warm up. Let's help him a little. Let's chat and let it freeze. Has cooled down. Let's try to pull it out. Let's go. I didn't calculate with tin. The middle boss was supposed to be a little longer, there was not enough tin, from which the slag did not float, nevertheless, the boss turned out. We will trim it with a file.
It is better to pour over the excess and remove with a knife than not to top up. Anyway. In general, it turned out not bad.
And here is the intermediate boss that I filled in earlier. The tin was heated with a large burner. It turned out no worse than the factory one.
I adjusted the end lugs to the shape, making them a little flat and smoothed out the sharp edges.
The cable is ready. Can be assembled by hand.
If you have a different bump shape. For example, such. This is not a problem. Drill the hole for the boss from the end of the bar, and for the cable from the top. Do not forget to fluff the end of the cable it will be more reliable.
But in order to get such a lug, the form will have to be split
Note. If you are changing the power window cable, it is important that these springs have free play.
If you don’t know what size the cable should be, make it a little longer. It is better to resolder one more boss than to change the entire cable. Here is a small and useful video.
Now you know that this is the best way to make cable bosses and you know how to repair a cable yourself.