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Elninio
06-02-2006, 10:04 PM
http://www.wiggle.co.uk/images/nokon%20cables%20new.jpg

this brake cable (for bmx bikes) is made of aluminum shells/fragments, however it is very expensive...
...so ive been thinking of makeing my own cable. What i plan to do is take the telfon tube of a regular cable and to buy these aluminum barrel fragments separetly, is there a place that sells these types of small aluminum pieces?

torker
06-02-2006, 10:43 PM
Christian (?) If you bought a lathe you should be able to make those parts with your eyes closed.
BTW...I spent a week with my nephew who rides pro and learned a whole lot about what ya'll do. It's pretty neat stuff.
I don't think I'd be trying one of those back flip things above 6" of solid concrete though.
Russ

Elninio
06-04-2006, 01:55 PM
i still havent bought a lathe =(, there were some small ones in the paper but too costly for the size and condition, also a used/abused southbend was on ebay but alot of people were following that and i was busy that week so i didnt get to bid :(

DancingBear
06-06-2006, 10:35 PM
This is really just a cosmetic cable housing, right? If so, try a jewelry supply place, they carry a staggering array of beads and such. http://www.firemountaingems.com would be a good start, usual disclaimers (just a customer, no other interest) apply.

It looks like it would be a really tedious job on a lathe.

Personally, I've never seen the upside of adding weight to a bicycle, but hey, it's a free country! :)

HTH

Walt

winchman
06-06-2006, 11:01 PM
I know zip about bicycles, but I think the segmented cable housing is much more than cosmetics. It makes the cable very flexible, but the length of the housing stays the same, and there's no give in it. That would make the "feel" of the brakes extremely consistent, and that seems very important.

I agree that making all those male and female spherical ends is going to be a tedious job.

Roger

Evan
06-07-2006, 02:27 AM
Think segmented adjustable coolant hoses.

bikepete
06-07-2006, 03:30 AM
Personally, I've never seen the upside of adding weight to a bicycle, but hey, it's a free country! :)


According to the manufacturer in Germany they're 40% lighter than the usual cables with their steel wire outers:

http://www.nokon.de/html/english/vorteile.html

A.K. Boomer
06-07-2006, 10:14 AM
Elninio, if you found a place that sold those actual segregated pieces you will end up paying WAY more buying them seperate and putting them all together, 40% weight savings in a cable housing is didly squat because the original stuff amounts to nothing to concider to begin with, put your money were it matters more like lighter wheels or tires, wheel weight is twice as hard to accellerate and twice as difficult to stop, you could make your bike 10 to 20 times faster (than what lighter cable housings will do) simply by shopping around and installing the lightest innertubes (6 to 8 bucks) rather than buying overpriced techno-weenie stuff (leave that to the rich fella's that dont know how to pedal a bike,,,,)

I know your riding BMX so you dont have gears but i went to the websight and they stated that they also sell this stuff for shift cable housing, I wouldnt put this on my Mt. bike if they gave it to me for free,,, In my H.O. this is a no no,,,, brakes ok but shifting housing you dont run two seperate materials (cable steel and housing aluminum) because index shifting is very precise nowadays, and aluminum expands and contracts 3 to 1 compaired to steel, this is a definite factor on a shift cable that runs the entire length of your bike, you wouldnt believe what it equates to in variance from a cold day to a hot one, it can be enough to change the way your bike shifts, always run steel with steel for shifting (it doesnt weigh barely anything)

Cheers

Elninio
06-10-2006, 01:38 AM
i already have a light bike, and im not obsessed with lightess that i would actually purchase this cable, my goal is to make these on my own so i can sell them (many of my freinds are obsessed with this cable, but they cant afford it), the weight is insignificant, therefore even if it is heavier than a regular cable, it wouldnt matter. The advantage to this type of cable is that there is no flex in it, aside from this the other options would be running a dual-cable set up or some sort of hydraulic brakes (however some people prefer the mono-cable set up). I dont have a lathe but i do have a drill press, what im thinking of doing is setting up my lathe chuck on the drill press so that i can but the cutting tools in the lathe chuck without having to re-adjust the setup, the aluminum stock would go in the drill press chuck, and as the quil moves down it also moves the stock into the cutting tool, for making concave ends i could use a rounded bit but how do i make the convex ends? Also the lenght of each aluminum segment isnt that crucial so Z axis precision on the drill press isnt a problem :)

Elninio
06-10-2006, 01:40 AM
so i would have on rounded bit, and some sort of lathe-type offset boring bar to make the convex ends, any suggestions?

Elninio
06-10-2006, 01:50 AM
<a href="http://photobucket.com" target="_blank"><img src="http://img.photobucket.com/albums/v329/Elninio_elninio/cableplan.gif" border="0" alt="Photobucket - Video and Image Hosting"></a>


heres a quick sketch i drew, im trying to make-do with what i have (which is a small drillpress and a 5 inch lathe chuck). Also note that there is no contact between the inner-cable and the cable housing (aluminum segments), the inner cable will be surrounded by a teflon tube, which is encased in the aluminum housing.

Elninio
06-10-2006, 01:51 AM
<a href="http://photobucket.com" target="_blank"><img src="http://img.photobucket.com/albums/v329/Elninio_elninio/cableplan.gif" border="0" alt="Photobucket - Video and Image Hosting"></a>


heres a quick sketch i drew, im trying to make-do with what i have (which is a small drillpress and a 5 inch lathe chuck). Also note that there is no contact between the inner-cable and the cable housing (aluminum segments), the inner cable will be surrounded by a teflon tube, which is encased in the aluminum housing.

Elninio
06-10-2006, 01:52 AM
oops! sorry about the double post..

Schutzhund
06-10-2006, 02:15 AM
How much do these Nokon cables normally retail for?

I found a several sets on ebay ranging from $40-$125

I think what people are trying to tell you is that you are looking at ALOT of work in trying to duplicate these cables, especially without the proper tools. Even with a lathe you are looking at ALOT of work.

If you are looking to make a profit by selling these to your friends...

Let me just say that I hope you are in it for fun and not the hourly wage.

Magic9r
06-10-2006, 06:44 AM
Thick walled tube or bar stock, form tools for each end shape (2), parting tool & a collet for each part type (2).

Drill hole to size.
Shape end with form tool
Part off
Make a bin full
Mount in custom collet to shape other end (of entire bin full)

Repeat with other form tool & collet for mating part.

Check for patents if you want to make & sell:eek:

Rustybolt
06-10-2006, 08:20 AM
That's a job for a screw machine.
Form, center, drill, ream,cutoff.

A.K. Boomer
06-10-2006, 10:32 AM
its also a job for CNC, thats how these little guys are produced, a quad-zillion of them every hour,,,, However - far be it for me to interfere with someones obsession cuz god knows i have enough of my own --- if your going to go through this trouble you might want to take into account that to increase the durability of these peices they really should be anodized and that will put a really hard skin on them, anodizing also makes the peices grow (2/10ths to 4/10ths?) so now would be the time to compensate, 6061 T6 aluminum would be a good material to start with, If you dont anodize you will end up with that ugly black crap between every single aluminum joint after every ride and not only will you be constantly adjusting you brakes to take up the slack but i guarrantee you you will have the ugliest cable housings out there!
good luck bro ,, whatever floats your boat.

Elninio
06-11-2006, 11:45 PM
im definitly in it for fun, but i could sure use a bit of extra cash, also my exams are next week so ill have a lot of free time after that