Strength of Solder for Soldering Bowden Cable Wire Nipples? - UK Vintage Radio Repair and Restoration Discussion Forum

BrianAllen · 12th Jun 2021, 8:08 pm

Just a quickie.

Can I use the same type solder we use for soldering wire for soldering nipples to Bowden cable wire?

Brian

G6Tanuki · 12th Jun 2021, 8:15 pm

What's the wire made of?

If it's steel or - even worse - stainless-steel - you will have problems getting ordinary solder to adhere to it.

[When I re-strung the dial drive on my Eddystone 840A rather than using any kind of solder I dismantled a bunch of 5-amp 'choc-block' connectors and sawed each of the barrels in half to produce a single-screw version; these worked just fine and have the advantage that you can release-and-retighten them if you need to take up a bit of slack]

BrianAllen · 12th Jun 2021, 8:23 pm

Just ordinary steel I think; definitely not stainless.

What a good idea, I like the idea of being able to release and re-tighten.

Thank you.

Brian

kalee20 · 12th Jun 2021, 10:37 pm

I've used standard electronics grade 60/40 solder for bike brake cables. Obviously, the cable must be clean, and spread out inside the nipple. I've never had one pull off.

But - I don't know how well lead-free electronic solder would work. It's not clear from your original post what you mean by "the same type solder we use for soldering wire," hopefully then this answer covers both eventualities!

Refugee · 12th Jun 2021, 10:38 pm

Last time I did one I used a crimp solder tag.
The ring part could be cut down if it makes threading easier.

TonyDuell · 13th Jun 2021, 4:46 am

When I needed a cable for the cover latch on my R80 disk drive I did what G6tanuki suggests and used cut-down 'chocolate block' innards. Seems to work fine.

The nipples I bought were designed for use on a bicycle and seem to be aluminium. No solder would stick to them anyway. So I didn't bother to check if the solder would stick to the cable or not.

trevatxtal · 13th Jun 2021, 6:41 am

"" the cable must be clean, and spread out inside the nipple"".
If the solder flows and the strands spread then it will not fail.
The adjustable clamp (however made) is a much better idea.

Restoration73 · 13th Jun 2021, 7:37 am

Trouble with 60/40 is it is ductile. A higher melting point 40/60 type is less so, a good
temperature controlled iron (or gas type) may be needed.

Radio Wrangler · 13th Jun 2021, 9:05 am

If you're going to gas heat, then silver solder might as well be used. It's a lot less ductile and shouldn't have a creep failure mode like soft solders.

Parts fail when under most stress, so nipples pull off when they're being used. For a bike brake this can be very dangerous. Soft solder would be worrying in some applications.

David

ms660 · 13th Jun 2021, 11:11 am

Inserted into a coupling then filled with a Tin alloy (white metal) very very strong, no pullie out.

Lawrence.

MotorBikeLes · 13th Jun 2021, 7:10 pm

I have been soldering motorcycle cables for the last 60 years, most of the time using normal electronics multicore. With some older stuff, with a hint of rust around, you will need some Bakers fluid to be sure of a good joint. As mentioned above, the creation of a "ball" in the Bowden cable is the guarantor of long lasting success. I have seen stainless steel, but never on a motorcycle, but possibly an acid fluxed wire would be OK provided wire "balled" properly. I have made all my own cables for most of this time and still do.

Les.

12th Jun 2021, 8:08 pm	#1
BrianAllen Heptode Join Date: Nov 2018 Location: Staffordshire Moorlands, UK. Posts: 595	Strength of Solder for Soldering Bowden Cable Wire Nipples? Just a quickie. Can I use the same type solder we use for soldering wire for soldering nipples to Bowden cable wire? Brian

12th Jun 2021, 8:15 pm	#2
G6Tanuki Dekatron Join Date: Apr 2012 Location: Wiltshire, UK. Posts: 13,998	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? What's the wire made of? If it's steel or - even worse - stainless-steel - you will have problems getting ordinary solder to adhere to it. [When I re-strung the dial drive on my Eddystone 840A rather than using any kind of solder I dismantled a bunch of 5-amp 'choc-block' connectors and sawed each of the barrels in half to produce a single-screw version; these worked just fine and have the advantage that you can release-and-retighten them if you need to take up a bit of slack]

12th Jun 2021, 8:23 pm	#3
BrianAllen Heptode Join Date: Nov 2018 Location: Staffordshire Moorlands, UK. Posts: 595	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? Just ordinary steel I think; definitely not stainless. What a good idea, I like the idea of being able to release and re-tighten. Thank you. Brian

12th Jun 2021, 10:37 pm	#4
kalee20 Dekatron Join Date: Feb 2007 Location: Lynton, N. Devon, UK. Posts: 7,085	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? I've used standard electronics grade 60/40 solder for bike brake cables. Obviously, the cable must be clean, and spread out inside the nipple. I've never had one pull off. But - I don't know how well lead-free electronic solder would work. It's not clear from your original post what you mean by "the same type solder we use for soldering wire," hopefully then this answer covers both eventualities!

12th Jun 2021, 10:38 pm	#5
Refugee Dekatron Join Date: Apr 2012 Location: Worksop, Nottinghamshire, UK. Posts: 5,553	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? Last time I did one I used a crimp solder tag. The ring part could be cut down if it makes threading easier.

13th Jun 2021, 4:46 am	#6
TonyDuell Dekatron Join Date: Jun 2015 Location: Biggin Hill, London, UK. Posts: 5,209	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? When I needed a cable for the cover latch on my R80 disk drive I did what G6tanuki suggests and used cut-down 'chocolate block' innards. Seems to work fine. The nipples I bought were designed for use on a bicycle and seem to be aluminium. No solder would stick to them anyway. So I didn't bother to check if the solder would stick to the cable or not.

13th Jun 2021, 6:41 am	#7
trevatxtal Triode Join Date: Sep 2016 Location: Brixham, Devon, UK. Posts: 35	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? "" the cable must be clean, and spread out inside the nipple"". If the solder flows and the strands spread then it will not fail. The adjustable clamp (however made) is a much better idea.

13th Jun 2021, 7:37 am	#8
Restoration73 Nonode Join Date: Jun 2013 Location: Surbiton, SW London, UK. Posts: 2,801	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? Trouble with 60/40 is it is ductile. A higher melting point 40/60 type is less so, a good temperature controlled iron (or gas type) may be needed.

13th Jun 2021, 9:05 am	#9
Radio Wrangler Moderator Join Date: Mar 2012 Location: Fife, Scotland, UK. Posts: 22,880	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? If you're going to gas heat, then silver solder might as well be used. It's a lot less ductile and shouldn't have a creep failure mode like soft solders. Parts fail when under most stress, so nipples pull off when they're being used. For a bike brake this can be very dangerous. Soft solder would be worrying in some applications. David __________________ Can't afford the volcanic island yet, but the plans for my monorail and the goons' uniforms are done

13th Jun 2021, 11:11 am	#10
ms660 Dekatron Join Date: Apr 2011 Location: Cornwall, UK. Posts: 13,454	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? Inserted into a coupling then filled with a Tin alloy (white metal) very very strong, no pullie out. Lawrence. Attached Thumbnails

13th Jun 2021, 7:10 pm	#11
MotorBikeLes Nonode Join Date: Dec 2012 Location: Kirk Michael, Isle of Man Posts: 2,350	Re: Strength of Solder for Soldering Bowden Cable Wire Nipples? I have been soldering motorcycle cables for the last 60 years, most of the time using normal electronics multicore. With some older stuff, with a hint of rust around, you will need some Bakers fluid to be sure of a good joint. As mentioned above, the creation of a "ball" in the Bowden cable is the guarantor of long lasting success. I have seen stainless steel, but never on a motorcycle, but possibly an acid fluxed wire would be OK provided wire "balled" properly. I have made all my own cables for most of this time and still do. Les.