Making your own cables?

[stevo as b4]

I'm sure a few folks on here have done it, but what's the consensus?

I need shorter throttle and choke cables for the new carb on my KMX 125, and seeing as it runs Pre-mix, I want to get rid of the 2-1 junction splitter on the throttle cable.

I've looked at getting Venhill engineering to make me up a set of custom cables, they need different fittings from standard and a different nipple on the throttle cable I think too. So I've marked up the old cables and was going to send them off to use as patterns. I'll send them the right fittings for the carb end too. The cost is £76+ postage think.

But I've noticed that they and other companies sell a kit to make your own cables, and with a variety of fittings, and cable adjusters etc. I need cables to finish putting the bike together, so I'm torn between buying a set of custom cables, or buying a kit and having a go at making my own?

Tl:dr, How hard is it to do at home, and what if any specific gear do you need to make them yourself? I've got a decent gas powered soldering iron with a mini blow torch function, for soldering on new nipples etc.

BCF advice please?

[1198]

My initial thought was just to use the old overlong cables but route them so as to disguise the fact...
Sorry if this doesn’t help much..

[stevo as b4]

There's no room to hide them neatly being a trail bike, and they need to be about 3'' shorter minimum compared to the old cables. I don't know I just see trying to use over long cables as a bit of a bodge maybe?

I'm trying to avoid any more bodges on this bike, as being a first year rare full power varient of the bike, I've been told that I really should restore it to 100% OEM standard on account of its rarity Oops!

[stinkwheel]

www.carrotcycles.co.uk

Making your own cables is a useful skill. A throttle/choke cable is the best to start with because there is little load on them.

Getting the free length right can be surprisingly tricky so get enough stuff to make a few if you're going to. Spare throttle cable and housing is never a bad investment anyway.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Easy-X]

While I was refurbing the oil pump on the old DT I did the exact same thing, replace the Y-cable with a single. I wouldn't say it's dead easy but certainly not as hard or expensive as say welding aluminium

I read this:

https://www.vintagebikebuilder.com/building-cables.html

The crucial things are flux and using lead-based solder. My personal tip is to get a generic "cable repair kit" that has lots of assorted brass ends, identify which ones you actually need and practice with the rest before making the final cable.
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Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[stinkwheel]