The throttle cable on my 59 Bugeye had been pretty thoroughly destroyed by 40
years of use, complete with kinks, rotted casing, and frayed ends. It finally
broke, and was too short to trim again. I am sure someone else has come up
with this solution, but it might bear repeating.
I went to a bicycle shop, and got a handbrake cable for about $6.00. From the
hardware store, I got a couple of feet of 3/32" stainless aircraft cable
($.45/foot), and two aluminum ferrules ($.20) to fit one end of that cable. I
also picked up a piece of thin brass tubing ($1.49) that just fit over the
outside of the outer part of the bike cable (but not over the chrome cable
end). This tube is to make a new cable end, as the bike cable is 55 inches
long and has to be cut. This is enough stuff for two cables. You can make a
spare, if you want.
Remove the old cable complete. Cut the "T" end off the bike cable wire, pull
it out, and toss it. Measure the outer cable, and cut with a pair of dykes.
Using a mini tubing cutter, cut about 1 ½" of brass tube. This leaves a nice
rounded tip on one end, and a square (original) tip on the other. Slide the
square end onto on the cut end of the outer cable, as far as it will go. Use
the tubing cutter to roll a groove around the middle of the brass tube, not
cutting through, but locking it in place.
Thread the aircraft cable through the outer cable, insert through the car body
fitting, and crimp the ferrule on the end, using vice grips. Hook it on the
pedal rod. Working under the hood, thread the cable into place, adjust,
tighten the lock screw, and you are all set.
If any of this is not clear, email me. Total cost is about $10, and it looks
very original.
Chuck
59 Bugeye
72 JPS Lotus Europa
85 Saab 900 Turbo
94 Saturn SL2
85 Labrador Retriever (Lady)
Two Cats (Penny and Jenney)
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