shortening cables - speedo or rev counter

[RDfella]

Have just found a spare Sumlog drive cable (a marine version of a car speedometer cable). If you think finding a NOS A7 longstroke crank or similar might be difficult, try finding one of these (especially one long enough to fit a particular boat). Naturally, the price reflects the scarceness. Of course, they need to be cut to length but, fortuitously, the square at the end is a separate item that slips onto the cable and just needs crimpling in place (using the totally useless tool suplied for the purpose).
What has this to do with our motorcycles? Wel, thinking about this cable reminded me of shortening the speedo and revcounter cables on the project and the need to re-form the square drive. In case it might be of use to others, I thought I'd put together an idiot's guide how to do the job. Attached is my attempt to describe the process - a bit long-winded as I was trying to avoid including diagrams. Those who have even half an idea how to do such things need read no further.

Edit - the attachment is in Word. Adobe opens it.
Also, I see some regret not having a mill to machine the necessary groove in the jig. Fear not - just mount an endmill in your lathe chuck and fasten the job to the toolpost.

[muskrat]

G'day RD.
Very well explained, thanks for taking the time.
I had similar when fitting an Indian Enfield speedo on the Cafe. To make the round inner square, I silver soldered the end 1" and ground it square with a grinder.
The things we do to keep the things we love to give us smiles.
Cheers

[Rex]

I've often wondered about shortening a speedo cable. Shame I can't open the above guide after down-loading it..

[berger]

me also rex I am not clued up with these modern thingy's. I get it in the machine and then it goes on about apps and this steam age device throws a wobbler and ruins all my regular stuff . maybe because I haven't got a clue what I am doing

[morris]

me also rex I am not clued up with these modern thingy's. I get it in the machine and then it goes on about apps and this steam age device throws a wobbler and ruins all my regular stuff . maybe because I haven't got a clue what I am doing

Converted the file to PDF for those who don't have Word.
Alternatively the original file can be opened with Apache's Open Office, a free downloadable programme which can open all Microsoft office documents

[Rex]

Thanks for that Morris.
Can you sort me out a milling machine now..

[RDfella]

I noted some bemoan the lack of a milling machine. Well, all is not lost. There's invariably a way around problems in engineering, so if you have a lathe, put an endmill in the lathe's chuck and mount the job on the machine's toolpost.

[Greybeard]

Always wanted a lathe. Until I retired I couldn't have justified the cost. Although I could probably afford one now there is no room for one at this house.   

[muskrat]

I noted some bemoan the lack of a milling machine. Well, all is not lost. There's invariably a way around problems in engineering, so if you have a lathe, put an endmill in the lathe's chuck and mount the job on the machine's toolpost.

G'day RD.
Yes Ive done that a few times. Also mounted an angle grinder on the cross slide.
Cheers

[berger]

muskrat you naughty boy I hope you cleaned it ALL

[muskrat]

G'day Bergs.
Yes of course. In fact I had to mount the Dremmel in the tool post last night to take a tad out of the id at the ends of a set of new valve springs. The collar and cups wouldn't sit in properly! Covered everything with plastic sheet and after wiped it all down with turps. Must look after the nice new lathe.
Cheers

[berger]

  good man, but I must admit my worn 70odd year old lathe wouldn't mind a bit more abrasive and I certainly wouldn't because I couldn't do precision turning with it even if I knew how to