The barrel at the end of my throttle cable is too big

The stock throttle cable's barrel is too large. I have the cut off ends from a throttle cable that has the correct size barrel. Is there any smart way to salvage the barrels and install them on the other throttle cable?

If not, where can I buy new barrels that can be crimped? soldered? bubblegummed on?

I guess the real question is, what's the proper method of putting the barrel end on a throttle cable?

maybe

drill out the throttle wheel to fit the larger barrel?

That sounds like a personal problem...

fasted58 wrote: maybe

Where does one find this magnificent piece?

mw wrote: drill out the throttle wheel to fit the larger barrel?

The cable needs to be shortened anyway, so I'd still be in the same place with having to put a new end on.

Taiden wrote:

fasted58 wrote: maybe

Where does one find this magnificent piece?

search aircraft supply: bug nut or control cable clamp

I used these on throttle and clutch cables for a DSR, they work.... most recently on dad's rototiller

I'll look for more links

A bike store that has supplies for BMX bikes should have those, I recently got some for a friend's exercise bike that had broken.

I make 'em on the lathe. Cross drill a piece of 1/4" brass rod, turn to diameter, drill and tap through 8-32, use a 8-32x.25 stainless cup point set screws ~from both sides~.

Last one I made is on the throttle cable of the DSR. No slip, easy adjust...

They have those at the hardwear stores in the paper boxes with other lawn mower parts.

I have one of theses kits. http://motionpro.com/motorcycle/partno/01-0055/ But holy crap theve gottem to be big $$ now. used to be less then $50...

+1 for any bike shop. Also get a little crimp on aluminum end cap to keep the cable from fraying. We called them Damnits when I worked at a bike shop. If you didnt use one, the cable would fray, and youd end up piercing your finger with a greasy nasty wire, and youd yell DAMNIT cuz that e36m3 hurts!

Any powered machinery repair shop should have those; esp if they service commercial lawnmowers. Also, try Ace hardware..

What's a DSR?

D sports racer. SCCA class for purpose built race cars w/ full bodywork. Miniature Lemans prototype cars sort of. 1000cc, minimum weight is something like 800#.

I have an early Radical Clubsport w/ a Suzuki GSXR1000 engine. Hoosier bias ply slicks in 7" front and 9" rear. It scales at about 1200#, and is legal crack, I sh1t you negative.

There's a couple pics in my garage.

On the LeGrand, I bought a brake cable from a tandem bicycle for my throttle cable--the barrel was too big, so I dremeled it down.

Per

perfect... I was thinking of a solution for my s10 build... this should do the trick nicely :)

Good topic I need to repair the throttle return cable on the carb on my punky buellster, right now it is kind of funky as without the throttle return the the throttle cable will loosen, but it hasn't been an issue yet.

Per Schroeder wrote: On the LeGrand, I bought a brake cable from a tandem bicycle for my throttle cable--the barrel was too big, so I dremeled it down. Per

hack.

Yep, spent $8 on the throttle cable--but then went and spent $80 on 3/16 braided stainless ptfe-lined hose. ptfe lining = smoother throttle.