Wednesday, November 27, 2019

Paramount Frame -- Installed the rear brake cable and housing

Rear brake cable housing and cable, as it meeting the rear brake caliper... 


The brake cable housing goes into the adjuster (by turning the adjuster, by gripping the black rubber portion). 


They call these type of brake levers "aero" style because the cables comes out the bottom.  Previously, the cable came out of the top of the levers and looped up then down.  The cable housing is routed along the handlebar and is hidden  


The rear brake cable housing is routed through the top-tube on this frame.  This is where the housing enters...

Better picture of the integrated cable housing entry point... 

This is where the housing exits the top-tube.  It was very difficult to route the housing through the top-tube.  Had to fish the end out by very carefully twisting the housing so that the tip would be close to the exit point.  Then used a small pick tool to guide the housing out of the exit hole.  Quite a dexterity challenge! 



The cable was cut to length and a cap piece was crimped on the end of the cable to keep it from unraveling.


This is a view of the bottom of the brake lever where the brake cable housing sits.  The large hole on these brake levers is NOT correct.  There's supposed to be a small hole, just for the cable to go through.  It looks like someone drilled these holes out.  I can't imagine why someone would do this!  In order to make these levers work, something with a smaller center hole but with an outer size larger than this hole needs to be used.  One this lever, I found a nut that would just fit inside this space but not push through.  The hole was small enough in the middle so that the brake cable housing could sit on it.  It's what the British would call a "bodge" but it works. 

This is a picture of another pair of brake levers that shows the right configuration.  There's a round flat surface that the cable housing is supposed to rest on & a small hole just for the brake cable to go through... 

For the LH brake lever for the front brake, I found a small hollow aluminum cylinder piece I can use as an adapter.  This picture shows the adapter piece just placed in the hole where the brake cable housing is supposed to sit.  It's just large enough that it doesn't go through the hole at the bottom. 

I drilled a slightly larger hole than this piece's original inner diameter, so that the brake cable housing can sit inside this piece.  The larger hole I drilled went about 3/4 of the way through the piece so that the cable housing bottoms out in this piece.

This is the end that I drilled out.  The wall thickness is less than in the previous picture.  You can also see that the larger diameter stops about 3/4 of the way down the center.  You can see the step where the drill was stopped. 

The housing fits perfectly in the adapter. 

You can see where the cable housing stops a few mm short of the end of the adapter.

Cable housing with adapter, as it would sit when assembled to the brake lever housing.


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