emergency brake cables

extremebuggy · Posted: Wed Nov 04, 2009 7:39 pm Post subject: emergency brake cables

I am replacing the emergency brake cables on my fiberglass buggy car, and I heard that the pan is shorten on these cars. So can anyone tell me where I can find an emergency brake cable that will be short to accomodate the shortened pan.

BL3Manx · Posted: Wed Nov 04, 2009 9:04 pm Post subject:

I would never use one of the clutch cable shortening fittings but I've never had any problem with these on my parking brake cables.

http://www.thesamba.com/vw/classifieds/detail.php?id=720600

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57streetrodbuggy · Posted: Wed Nov 04, 2009 9:57 pm Post subject:

they are pretty good but for some reason they dont sit flush against the E-brake handle (or at least they dont with the cheap chrome E-brake handles). mine actually angled out away from the handle because the lower part was too wide and hit the handle before going through the little bracket on top. i ended up grinding off some of the excess metal from the shorteners and cutting a bit out of the E-brake handle mount on the tunnel to give them clearance.
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Dale M. · Posted: Thu Nov 05, 2009 8:22 am Post subject:

Determine the length you need and have custom cable made....

http://www.push-pull.com

Yes they do custom length VW brake and clutch cables....

Check last page of "products" sheets (pages)....

Dale
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bornred62 · Samba Member Joined: January 09, 2005 Posts: 203

I've used the ones above for years with no problems.Just a few things you need to do. First of all get rid of the chrome e-brake handle.
Pick up a later model handle that has the pivot and the mounting bracket.
mounts on the pivot and the threaded ends go through. Gets them away from the handle a bit. then put the shortener in a vise and drill it deeper
so more cable goes into the end. I also drill on the other side of the set screw a little higher and install another set screw. It aint coming out.

Gene C · Samba Member Joined: March 31, 2007 Posts: 153

I learned a neat install of the shortened cable
Was to take the longest length cable and then cut it ( right about the rear of the tunnel) and over lay them with two U clamps to splice them together
That way you have the stock threads that fit coming through the handle
easy to get the right length and adjust
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Burlingame Ca

BL3Manx · Posted: Fri Nov 06, 2009 9:21 am Post subject:

extremebuggy · Posted: Thu Nov 12, 2009 5:58 pm Post subject:

BL3Manx · Posted: Thu Nov 12, 2009 6:08 pm Post subject:

The shortened cable goes inside the hole on the end of the fitting then the set screw is tightened. Make sure the set screw is backed off so the cable goes all the way to the end of the hole. Once its in all the way, tighten the set screw hard.

Use a Dremel with a thin cut off disc to cut the cable. It also helps to wrap some masking tape around it at the place you cut. You don't want the strands to unravel when you cut it.

Glasser · Posted: Thu Nov 12, 2009 7:38 pm Post subject:

Another way to cut them is with a wire feed welder. Just don't hang on to the cable while welding / cutting it, it's gets dam hot fast! The welder will melt the cable in half and weld the ends closed so no fraying. Some trial and error to get the heat set right but works nice when you get it right.

I used the chrome handle and ran into the same problem. I modified it with the old type system so got he best of both worlds Smile

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My build up http://www.thesamba.com/vw/forum/viewtopic.php?t=265364&postdays=0&postorder=asc&start=0
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Mongo63 · Posted: Fri Nov 13, 2009 12:23 am Post subject:

lostinbaja · Posted: Fri Nov 13, 2009 5:50 am Post subject:

I usually drill the set screw hole all the way through so when the set screw is tightened the cable has a couple more corners to add extra friction to keep the cable from slipping.
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