Broken Trunk Lid restraint cables

[agedbikeman]

When I got my wing 1 week ago I noticed both of the cables that stop the trunk lid falling backwards were broken, ther're still available on my side of the world at 8GBP each,so I set about making my own.

DSC02095.JPG I used some electrical wire and a piece of 6mm alloy tube, cut 4 pieces and drill a hole in each, open out the end clamps and discard the old cables, bare the electrial wire about 10mm each end and pass it through the hole in the piece of alloy tube[attachment=1]DSC02098.JPG

Fold the bared end of the wire in 3 and apply a huge blob of solder to stop it being pulled back through the hole

Fold the end clamps round the new ends and refit to trunk lid

Somehow managed to get the photos in reverse order,I'll get the hang of it one day

[NOVAwing]

When I got my wing 1 week ago I noticed both of the cables that stop the trunk lid falling backwards were broken, ther're still available on my side of the world at 8GBP each,so I set about making my own.DSC02095.JPG
I used some electrical wire and a piece of 6mm alloy tube, cut 4 pieces and drill a hole in each, open out the end clamps and discard the old cables, bare the electrial wire about 10mm each end and pass it through the hole in the piece of alloy tube[attachment=1]DSC02098.JPG


Fold the bared end of the wire in 3 and apply a huge blob of solder to stop it being pulled back through the holeDSC02101.JPG

Fold the end clamps round the new ends and refit to trunk lid

Somehow managed to get the photos in reverse order,I'll get the hang of it one day

Nice work around you did there.

My used bike all were broke except 1.
So I bought them all from cyclemax.

If they ever go away and I have need again I will do as you did.
Nice work!

[Charlie1Horse]

But, the electrical wiring doesn't have the tensile strength as the original cables so, I think that they probably won't last very long. I would be more likely to get some steel cable of the same diameter as the originals and then try to do the same thing as you did here. Good luck!
Russell

Those who say it cannot be done should try not to interrupt those who are doing it.

[agedbikeman]

The point is, at least for now they are working for now, I don't expect it to last forever, last time I bought steel cable it wouldn't solder, my next experiment will be to buy a bicycle cable with the same size nipples, cut and adapt it. I live in the north of France, things like that are as common as hens teeth, you have to take what you can get, and if you're not an engineer with a shed load of tools you just have to go without.

[WingAdmin]

But, the electrical wiring doesn't have the tensile strength as the original cables so, I think that they probably won't last very long. I would be more likely to get some steel cable of the same diameter as the originals and then try to do the same thing as you did here. Good luck!
Russell

Those who say it cannot be done should try not to interrupt those who are doing it.

I was thinking the same thing - copper is VERY soft and stretchy, they won't last long.

I like the idea of adapting some bicycle cables. You could likely solder ends onto them just as if you were doing a throttle or clutch cable.

[Charlie1Horse]

Nice idea about the bicycle cables. I hadn't thought of that yet. One end is fixed solid on the cable and the other is fixed with a set screw. Cut to length and add a piece of heat shrink tubing (for appearance) and it would look just like the original. Thanks for the idea.
Russell

Those who say it cannot be done should try not to interrupt those who are doing it.

[CrystalPistol]

I saw a trunk damaged years ago when a fellow opened it and let go. It had a trunk rack and trunk bag on the rack with stuff in it. I sometimes carry rain gear up there, so it concerned me since those cables are so near the hinge axis. I made this strap from 1" wide nylon webb belt stuff, put on in the trike's trunk as well as my 1200's trunk. The stitches are easy. Never hindered my use of trunk either, and easily made adjustable.

[1goldwingnut]

GREAT. Now I have another project to start. I was good at simply soldering ends on cables too.