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Extending a throttle cable (Read 102 times)
Eegore
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Extending a throttle cable
08/28/17 at 06:00:36
 
 Ok so this isn't going on a motorcycle.

 I am using a throttle assembly from a bike and hooking it to a chainsaw.  The issue is that the cable ends do not match obviously so I am thinking the best bet is hooking the two together.

 The cable coming out of the chainsaw needs to be spliced/clamped whatever to the cable coming off the bike throttle.  The cable travels about 1/2 inch.

 Any ideas?
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Dave
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Re: Extending a throttle cable
Reply #1 - 08/28/17 at 06:13:45
 
You can either get a throttle cable kit from Venhill:

http://www.venhillusa.com/venhill-universal-motorcycle-throttle-cable-kit-192...

Or you can go to a good bicycle repair shop and buy the needed inner/outer cable and make your own ends out of brass.  I really like the bicycle stuff as it is often teflon lined and works really smoothly.  The stainless cables do require a special flux to make the solder stick.  I have also found that it is really easy to overheat a cable when you attempt to tin the end of the cable using a torch - it is easier to heat up a pool of solder on a scrap piece of metal - then dip the flux coated cable end in the solder pool until it is tinned.
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Eegore
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Re: Extending a throttle cable
Reply #2 - 08/28/17 at 06:35:35
 

 I was hoping there was some sort of crimp method.  

 I have the original cables but they aren't connected.  Are you suggesting I just strip out the current cables and try to make a custom length?
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Re: Extending a throttle cable
Reply #3 - 08/28/17 at 06:45:24
 
Yes.....build your own cable.

Vehnill has some cable ends with set screws - look through their stuff.

http://www.venhillusa.com/products/cable-kits-and-parts.html?p=2
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Re: Extending a throttle cable
Reply #4 - 08/28/17 at 06:47:53
 

 Ok I will check it out.  I don't know how the chainsaw cable connects to its internal component, hopefully its an easy attachment.
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Re: Extending a throttle cable
Reply #5 - 08/28/17 at 07:00:12
 
Chainsaws can either be a very stiff bent wire between the trigger and the throttle - or they could be a cable.
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Re: Extending a throttle cable
Reply #6 - 08/28/17 at 07:09:49
 

 Its a cable for sure.  I have the trigger/safety mechanism removed and the cable end is sticking out, its just not long enough.  

 If I can get to the internal connection without breaking anything and see how it connects then I'm good.  if not I have to hook the two together just outside of the chainsaw housing.
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justin_o_guy2
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Re: Extending a throttle cable
Reply #7 - 08/28/17 at 09:22:30
 
You might have to build a bridge between the shielding coils that the connected actuator wires can travel in.
Look at copper tubing fittings.
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Re: Extending a throttle cable
Reply #8 - 08/28/17 at 09:52:48
 

 So the cable coming out of the chainsaw needs to be reinforced. At the end of the insulating cover there is a plastic block that keeps that insulated section from pulling out of the housing.  

 I will most likely need to keep that section of chainsaw handle that holds it in place and connect the cables together after, or fabricate a custom cable if I can.  I really wanted to remove all of the original handle trigger assembly.
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Re: Extending a throttle cable
Reply #9 - 09/03/17 at 10:37:34
 

 So his is specifically my problem.  I need to clamp the smaller cable from the chainsaw to the larger throttle cable.  Running a whole new cable isn't an option unfortunately.  

 I also need to come up with a way to secure the throttle cable feed inside that handle but for now I need some method to allow the cables to connect and move 1 inch.

 I contacted the website linked here and dropped by 3 bicycle shops and nobody had a method to secure two cables together.  So I'm still looking for ideas here.
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justin_o_guy2
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Re: Extending a throttle cable
Reply #10 - 09/03/17 at 10:57:26
 
Get the end of the sheath out of the cup in the handle.
Get the gray cap off the extension.
Chop the BB off? Maybe, it could be a friend.. depends..
A piece of copper, I like the connectors, they are stiff. Tubing slipped into the ends, with a slot for fitting.
The end you're adding to, clean up the curved tube and solder.
The old end, clean, fit, epoxy and crimp.
Connecting the cables can be as simple as cleaning and soldering or a splice and solder.
How long you need it to last is the determining factor.
Build a mount block and secure in the handle. The curved end is something to work with.
A single strand of copper wire wrapped around the cables, fluxed, and soldered, will make a good connection.
After the parts are scrounged, about three hours.

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Re: Extending a throttle cable
Reply #11 - 09/03/17 at 11:59:13
 
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Re: Extending a throttle cable
Reply #12 - 09/03/17 at 12:43:01
 
 I've never soldered before, if I have time to go buy a kit and learn how that might be the way to go.

 If I can get a knarp to fit in there it might work.  I'm surprised there's no sleeve out there that could be crimped.
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justin_o_guy2
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Re: Extending a throttle cable
Reply #13 - 09/03/17 at 20:54:54
 
How many would get sold in a year?
5? Phhht..

Just connecting the two cables won't solve it.
I described how to connect the housings.
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Re: Extending a throttle cable
Reply #14 - 09/04/17 at 17:55:58
 

 Why wont connecting the cables work?  

 They would sit within the handle of the chainsaw.
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