How can i make my own flex for a K&b 3.5 elec..conversion

[99z286spd]

I have some spare .150 flex and was wondering how I can make my own shaft for my outboard? I just don't know how they get the square ends on the cable.....do I put it in a vise.?
Thanks for any help in advance
Leon

[Steven Vaccaro]

I watched a speedo shop do it, they used 2 metal blocks with a square slot cut in it. Put them together with the cable inside and hammered it.

[m4a1usr]

There are several methods you can employ. But first I recommend you tin the ends after cutting them to the right length.

1st method You will need a smooth jawed small vise or use some material to keep the jaw serrations from marring the flex shaft. Basicaly you clamp the flex with a some of it sticking above the jaws. Using a file cut a flat on it. This will be your first 90 deg surface. You have 3 more to file. Pull the flex with the one side ground down out if the vise and rotate it 90 degrees using the new flat spot as your timing index. The idea is file an equal amount, both depth and length, on each side of the flex material. If you tin the ends with a generous amount of solder before starting this you will end up with 90 degree edges at each corner. It takes a good eye to do this method right but its no where near as bad a balancing and sharpening a prop.

2nd is similar to Steve's method as you need to have a clamping block made or you need to make one. Make it from 3/8" plate steel and you will need two pieces. You will need to mark it for accuracy as it will need to make repeatable pressure clamps. A shallow 45 degree cut, one half the width of the flex width needs to be cut in to the face of each piece. This fixture will be put in a large bench vise and press the flex into the shape you want. Works good but its more for a person who wants to make many.


John

[Kris Flynn]

I make lots of shafts for the Nitro guys. I have two pieces of steel with a V cut in each and press the cable in a press. This is the best way to do it.

[Andrewg]

Leon

alternatively you could as head down to an instrument shop or cable maker. My local VDO shop puched out several on the spot and did not want payment.

[99z286spd]

Thanks guys for all the replies.... I was away for the holiday. What is a VDO shop?

In the mean time ..I think the shop next to my work can make me the steel plate pieces I need. Thanks again. This forum is extremely helpful.
Leon

[Andrewg]

Leon

VDO is a brand of auto and marine dashboard instruments. So a shop that services speedos and cable driven instruments.

Just FYI the website is here and they have some sort of tie in with continental tyres. I learn something everyday! http://www.usa.vdo.com/generator/www...e/home_en.html