Custom Bowden Cables?

Paul,
I've made several cables for my sailplanes. The "Bowden" cable is a
bicycle or motorcycle cable. Invented by Mr Bowden of the Raleigh Bicycle
Co. around 1900. You can get cable anchor bolts to fix the ends or silver
braze the end on with hard silver solder with a propane torch. Go to a
bicycle shop or motorcycle shop, get a brake cable and casing with one end
that will work on your sailplane. Buy the best brake cable (do not use gear
cable) housing with plastic lining and a die drawn wire (real smooth). It
looks like flanders cable has all you need. if you cannot find it locally.
Be sure to lube the cable with a cable lube found at bicycle shops when you
install it I use a 50% silver brazing material with silflux for flux. found
at welding shops. Make sure the fitting and wire is free of any oil or dirt
before brazing. Also like was said, the silver will run up the cable and
make it very stiff near the brazed fitting. The cable will come with 2
ends so, cut the end off you don't need and use the other end where you
need the most flex.
A new cable will improve the power of your brakes. Test your job by
squeezing the lever real hard to see if the end will come off. After
testing, you may need to turn the adjusting barrel to tighten the brakes.
Watch out, on the first landing because the brakes may be more powerful
than before.

Ed Gaddy
Cycle Logic