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Due to buying a year change Volvo I am unable to buy anywhere a new short handbrake cable for my car, Volvo will sell me at great expense 3 NEW cables and HB lever assembly. Reason I need a new cable is that the previous owner must have had HB issues (problem was actually the calipers) he/they/she tightened fully then tightened some more the HB lever adjusting nut… so much they threaded it. I tried to remove the nut, threaded part snapped, at least I could get it out from the car. I found a correct length bolt and cleaned the cable end up, now I can weld a bit, not sure I know what to do with these. Any help (if you are in Liverpool feel free 👍) or advice gratefully accepted 🤞   |
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Bicycle x1
Alfa Giulietta (now wife's)
Alfa 156
BMW 630i
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Can't quite see in the pic (I'm old and my eyesight is bad!) But is there enough thread on the sheared part to start a nut on it, and then feed the bolt in the other side, and then weld it?
It'll keep it all aligned, so long as there's enough clearance to have the nut permanently in place when the assembly is back in the car
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Nope, snapped right at the square bit, if a repair can be done it really can not be bigger, wider than the square.
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Bicycle x1
Alfa Giulietta (now wife's)
Alfa 156
BMW 630i
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What Volvo is it and what year? Finding a used cable has got to be a better bet?
Or use a company like Speedy Cables to make you one?
Nick
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1967 Triumph Vitesse convertible (old friend)
1996 Audi A6 2.5 TDI Avant (still durability testing)
1972 GT6 Mk3 (Restored after loong rest & getting the hang of being a car again)
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What Volvo is it and what year? Finding a used cable has got to be a better bet? Or use a company like Speedy Cables to make you one? Nick 2005 s40, I have been trying to find a used one, no luck so far, did not know about Soeedy Cables, I’ll talk to them, thank you. |
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Bicycle x1
Alfa Giulietta (now wife's)
Alfa 156
BMW 630i
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What's stopping you grinding each end into a point and welding? What’s stopping me ?, I’ll tell ya, I hadn’t thought of it 😃 My welding experience consists of patching inner wings, at first terribly. |
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Bicycle x1
Alfa Giulietta (now wife's)
Alfa 156
BMW 630i
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Darkspeed
Club Retro Rides Member
Posts: 4,665
Club RR Member Number: 39
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Welding 2 bolts togetherDarkspeed
@darkspeed
Club Retro Rides Member 39
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What's stopping you grinding each end into a point and welding? What’s stopping me ?, I’ll tell ya, I hadn’t thought of it 😃 My welding experience consists of patching inner wings, at first terribly. Well if you find yourself near North Shropshire happy to do it for you - But all you do with that sort of repair is drop the threaded section into a drill and then spin the part against a flap wheel at a 45 degree angle - then you produce the same on the square end - or just do pyramid preps against a grinding wheel. - For the welding do a couple of practice trials on some old bolts cut in half - you can then decide if your welds are good enough by doing some destructive testing. Alignment of the the two halves should not be difficult - bit of old angle or in a vise - I doubt perfect linear alignment is critical but you should be able to achieve "as near dammit" |
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Due to buying a year change Volvo I am unable to buy anywhere a new short handbrake cable for my car, Volvo will sell me at great expense 3 NEW cables and HB lever assembly. It's not this one is it? link |
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1988 Mercedes w124 superturbo diesel 508hp
1996 Mercedes s124 e300 diesel wagon
1990 BMW E30 V8 M60 powered!
1999 BMW E46 323ci project car
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I'd be very reluctant to trust a weld on that. Best bet is a new cable. If not available of the shelf have one made.
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Due to buying a year change Volvo I am unable to buy anywhere a new short handbrake cable for my car, Volvo will sell me at great expense 3 NEW cables and HB lever assembly. It's not this one is it? linkAlas no, there are hundreds like that, 105mm short 🙁 |
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Bicycle x1
Alfa Giulietta (now wife's)
Alfa 156
BMW 630i
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Darkspeed
Club Retro Rides Member
Posts: 4,665
Club RR Member Number: 39
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Welding 2 bolts togetherDarkspeed
@darkspeed
Club Retro Rides Member 39
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I'd be very reluctant to trust a weld on that. Best bet is a new cable. If not available of the shelf have one made. Why? |
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If all the cables available are too short why cant you extend one with a piece of studding and a studding coupler?
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Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,712
Club RR Member Number: 34
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Welding 2 bolts togetherDez
@dez
Club Retro Rides Member 34
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I'd be very reluctant to trust a weld on that. Best bet is a new cable. If not available of the shelf have one made. Why? Because you get a WEZ either side of the weld which basically becomes a grade 1 bolt. That will be 8.8 minimum, on something as small as that it will probably compromise its strength too much. Brazing would be a better repair, it’s how I’d do it if I had no choice, but I’d only do it for one of my own vehicles not a customers. The other option is buy a cable shortening kit, grind the remains of the old one on and fit it. Can also hard solder it on for belt and braces. |
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Last Edit: Oct 7, 2022 8:13:30 GMT by Dez
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Darkspeed
Club Retro Rides Member
Posts: 4,665
Club RR Member Number: 39
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Welding 2 bolts togetherDarkspeed
@darkspeed
Club Retro Rides Member 39
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Its a cable crimp with a thread on - it will be a far more malleable grade steel for a cable pull crimp than an 8.8 bolt grade - hence it snapping like it has and the nut cutting a thread in it. I do not see brazing being better in this application and care would have to be take re over heating the crimp - at which point you are then soldering the crimp and heating and compromising the cable etc. etc. etc.
But yes not for a customer - they would get a new cable - its their money not mine.
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slater
Club Retro Rides Member
Posts: 6,390
Club RR Member Number: 78
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Welding 2 bolts togetherslater
@slater
Club Retro Rides Member 78
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I'd just buzz it up and see what happens. It's not life and death.
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Make another fitting - a simple lathe job - and silver solder it to the cable.
Find your local supplier of winch cables, a yacht chandler or anyone else who deals with cables and get them to make a new cable using the damaged one as a pattern.
One of the cheap hydraulic cable crimpers on Ebay might be a suitable tool for this sort of thing.
Or you could weld the broken bits back together, but I'd be more concerned about the cable breaking afterwards from the heat rather than the fitting.
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I would be inclined to drill and tap both ends to take a smaller threaded insert (or a cut-down thinner bolt) to lock the two together, then run a bead of weld around them.
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I would be inclined to drill and tap both ends to take a smaller threaded insert (or a cut-down thinner bolt) to lock the two together, then run a bead of weld around them. There's no need for the insert to be threaded; a tight fitting pin will do. It's only a handbrake cable, not a suspension bridge repair  |
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Yes, true, although a threaded insert gives an added bit of strength to the repair.
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