How to treat those pesky cut cable ends

[Dan_]

[Tom H]

I've cut cable with O/A torch, welding the end, but that puts a small ball at the end that needs grinding down.

I like this Twist Welding method.  Can't wait to try it out.

[Bob S.]

I like the twist welding, too. But really like the electric glider!!!!
The way of the future. Too bad they didn't get full FAA blessing!  Surprised?? Not me....
The batteries are NOT "fuel" and must be counted as part of the 254 weight

[stevejahr]

That is very cool... now I need to go buy all new cables for every bicycle I own and try it out.

[ianahner]

As a builder of bicycle frames, I have been exposed to this conundrum for quite a while.

This method is genius, but a little bit of a pain in the butt due to the drill needed. The way I've taken to doing it on bikes is actually silver brazing them. Harris 56% silver rod and a little bit of flux makes an amazing cable termination. The silver is very low temperature as well, though I typically have an oxy-fuel torch ready to go and therefore use it, this can be done easily with just a propane blow torch from a local hardware store. Because this method doesn't get the metal hot enough to melt, the balling issue that comes up with welding is non-existant.

I'll try to take a couple pictures of the results. I may try the drill twist-weld thing at some point, but as far as I am concerned, it doesn't get much easier than dipping the cable end in a jar of flux, hitting it with a torch and touching it with a filler rod. Takes less than a minute.

Cheers guys!