Custom Throttle Cable
Posted: Thu 06.08.2009, 17:03Due to having slack in the throttle cable I couldn't adjust out using the facilities at either end, I decided I'd have to remove the cable and either repair or replace it. I had the same trouble as some others trying to remove the rubber bulkhead grommet and ended up having to cut it out. Not that it matters, as once the cable was free I saw how damaged it is - not only has the inner apparently stretched nearly two inches (!) but the outer is broken in several places. The plastic clip that attaches to the pedal was also bent out of shape.
My first thought was to get a Lotus replacement, but I've decided not to, for three reasons:
1) The price is £37.65, fairly expensive for such an item.
2) The cable clearly has a problem with stretching over time and not enough adjustment to take up the slack.
3) If fitting the replacement grommet is half as hard as getting the original off, I don't even want to try.
I've designed a cable upgrade to address these issues. I'm currently working with a supplier (Venhill Engineering) on a prototype, so in a couple of weeks I should be able to supply these to anyone who wants one. However, it'd be very helpful at this point to gauge interest. Price will depend on the number ordered, but I'm aiming to keep the parts cost down to around £10 so they'll probably represent a good saving compared to the Lotus option. It also depends on whether I just order the components and make up the cables myself or have the supplier do the cutting, assembly & brazing.
If I make them up myself the soldering will be done properly, using aerospace-grade high temperature brazing alloy. If the supplier do it, well, they've been making these things for 35 years so I'm pretty confident that they know what they're doing.
Details include:
- stronger inner cable, should reduce stretching.
- high-quality conduit with teflon lining to minimize cable friction & stick-slip in throttle action.
- all-metal fixings including clevis pin assembly at the pedal end.
- all fixings and cable are zinc-plated steel, nipples are corrosion-resistant brass.
- slightly longer adjustment range than stock at the throttle end.
- additional ~12mm cable adjustment at the conduit / bulkhead fixing point.
- new bulkhead fixing hardware to replace the stock rubber grommet & plastic ferrule. This will be very easy to fit, but provide a better flexible seal and more secure attachment. It'll also be easy to remove, adjust and reuse.
As an added bonus, there'll be a choice of PVC-covered or stainless steel braided conduit for those who like their cables sparkly. The PVC conduit will come in black as standard, but there may be options for yellow, silver, red and blue - I still need to check availability with the supplier for this though.
So... any takers?
Adam
My first thought was to get a Lotus replacement, but I've decided not to, for three reasons:
1) The price is £37.65, fairly expensive for such an item.
2) The cable clearly has a problem with stretching over time and not enough adjustment to take up the slack.
3) If fitting the replacement grommet is half as hard as getting the original off, I don't even want to try.
I've designed a cable upgrade to address these issues. I'm currently working with a supplier (Venhill Engineering) on a prototype, so in a couple of weeks I should be able to supply these to anyone who wants one. However, it'd be very helpful at this point to gauge interest. Price will depend on the number ordered, but I'm aiming to keep the parts cost down to around £10 so they'll probably represent a good saving compared to the Lotus option. It also depends on whether I just order the components and make up the cables myself or have the supplier do the cutting, assembly & brazing.
If I make them up myself the soldering will be done properly, using aerospace-grade high temperature brazing alloy. If the supplier do it, well, they've been making these things for 35 years so I'm pretty confident that they know what they're doing.
Details include:
- stronger inner cable, should reduce stretching.
- high-quality conduit with teflon lining to minimize cable friction & stick-slip in throttle action.
- all-metal fixings including clevis pin assembly at the pedal end.
- all fixings and cable are zinc-plated steel, nipples are corrosion-resistant brass.
- slightly longer adjustment range than stock at the throttle end.
- additional ~12mm cable adjustment at the conduit / bulkhead fixing point.
- new bulkhead fixing hardware to replace the stock rubber grommet & plastic ferrule. This will be very easy to fit, but provide a better flexible seal and more secure attachment. It'll also be easy to remove, adjust and reuse.
As an added bonus, there'll be a choice of PVC-covered or stainless steel braided conduit for those who like their cables sparkly. The PVC conduit will come in black as standard, but there may be options for yellow, silver, red and blue - I still need to check availability with the supplier for this though.
So... any takers?
Adam
alexg
(the only thing that has put me off getting new ones has been the price and ease of fittment - both of which you have addressed 
)