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Father/Daughter Project - Part 16

Filed In: Process

Father/Daughter Project - Part 16

Monday, February 3, 2020   |   Chris Blandford

Getting closer.

21. Cable Routing

Now that I have the rear brake mounted, I can determine how I want to run its cable. I begin by installing some handlebars, and cutting a piece of housing. I hold the housing up to the frame, play with it until I’m satisfied with the run, and make marks with a Sharpie. For this bike, I decided to run the cable internally, in full-length housing. It will run from the bars, around the non-drive side of the head tube, and into the underside of the drive-side top tube. It will make its tube-exit in a spot that I hope minimizes how far out the v-brake noodle will protrude.

I understand that most (proper?) internally-run cable housing runs through a brazed-in brass or stainless tube (and is done up front, before any tubes are connected together). I decided here, however, to merely braze on a little reinforcement plate and drill an angled hole for the cable. (This is similar to how I’ve internally-routed lighting wire in the past.) I’ll probably do something different on the Father bike--we’ll see.

I cut out, cleaned up, and (silver) brazed on the reinforcements. Then I drilled a hole in the tubes, and used files to enlarge and angle the holes for the housing. Once done, I test fit the cable. Upon doing so, I found that the cable bends were a little sharp entering and exiting the tube. I pulled the housing and “flattened out” (?) the holes a bit more. All good. The brake pulls pretty nicely, I think.

I thought I was just about done with this bike. While working on these bits, however, I decided that I wasn’t going to be happy with any short, off-the-shelf, 1” threadless stem (if I could find one at all). I've decided to go ahead and make a stem.

So, next up: make a stem.