Trimming outer cables

[Phil C]

Hello all,

Another very basic question from me.

I've just trimmed a mm or two off a damaged end of the black plastic outer cable of my choke, because the little metal ferrule wouldn't go over it. But now the little metal ferrule won't reach it, whereas of course it should overlap it. See photo attached. So I guess I now need to trim a few mm off the wound metal bit of the outer cable in order that the ferrule will reach the black plastic bit. How do I trim that wound metal bit without damaging the inner cable? Or have I messed up? Thanks in advance for your advice again.   Phil.

[chaz]

obviously you dont want to un solder the nipple either end you have a couple of options, well, 3 possible
1. large sharp sidecutters, but can be fiddly and may damage inside of outer cable.
2.  narrow hobby hand saw carefully  down and flex until near the end.
3. angle grinder with a narrow cutting blade. careful as you get near depth.

bear in mind, you are only cutting through one twist not the full diameter. so approx 1,5mm wide and same depth, only thing is that when cut through you might have an angled end, but will be hidden under ferrule. so I would go #2 or #3 and best held firmly NOT crushed in a vice.

edit..
just to add , some black insulation tape would cover the bare metal or if you do want to cut the outer, pull the inner right out and put some tape around inner then pull back in, should stop marking the inner.

[AdrianS]

Remember if you trim the outer cable a little, you are making the inner correspondingly longer.
I would not worry about the ferrule not reaching the black plastic. It will be fine.
If you want to trim a little of the inner the easiest way is with a thin cutting disc in a Dremel but you have to be very careful you don't touch or cut the inner cable. It is easy if the inner is removed but this is not always possible if there are nipples on the ends.
Personally, fix the ferrule in place and ignore the tiny bit of the metal inner you can see!

[Richard Mills]

How about using some heat shrink tubing over the black outer, and extending over the bare inner either going over or under the ferrule.