Cut Flexi-Shaft

[CeilidhKeith]

I have got to shorten a flexi-shaft for my boat ,i am going to use a Dremmil how can i stop any of the wire from twisting off when cutting.Any help would be appreciated thank you.

[siberianhusky]

Wrap a couple layers of masking tape around the shaft then cut it, the tape will hold it all together, then give it a good cleaning with brake cleaner and put a bit of solder on the end to keep it from unravelling.

[G-UNIT]

I always solder the section that I cut before I cut, I feel this lets the solder flow into the flex shaft and then I don't worry about the end unraviling, then I round off the end with the dremmil which allows the shaft to enter the collect smoothly JMO.

[siberianhusky]

Thats a good idea, I actually use a mig welder on the cable end. Takes me about 2 seconds. Not something every rc boater has in their shop though. Then I smooth the end on the belt/disk sander.

[CatMan]

Nope.... a mig welder was not on my list of rc boat tools to get. but if you got it, might as well use it. too bad it takes so long to use ( 2 seconds) How about a plasma cutter to get it done quicker?...LOL.
after you solder shaft, do you cut just past where the solder is? or make your cut so you have solder on both sides of your cut? a new flex shaft is the 1st. thing on my Genesis upgrade list.
just need more time to get brave enough to do it.

[JIM MARCUM]

I've cut many a flex cable from 4mm to 1/4" thick. I don't use solder (or use a mig like Mark) cuz I don't like heating up the cable & risking de-tempering it.

I use a 1" dia X 1/32" thick cutting wheel in a Dremel & work my way around the cable, quenching it in water as it warms up. Never had the cable strands un-ravel or get twisted up that way. Perfect cut every time. JIM

[CatMan]

anything that doesn't need soldering is good for me! you just dremel cut it without taping it or anything? I've never cut one but will need to soon.
I like your way....but I'll probably go through 3 shafts to get one right, but you gotta learn sometime at least for now I have the "i'm just a beginner" card to pull out when needed.... and will use it often....My screen name should have been cata-moron-man.
and to Mr. Marcum (don't send someone to pee on my porch, for calling you Mr. Marcum) I just noticed your text tagline below your message with Purple Heart Viet Nam Vet, and wanted to thank you for your service!!
I say this to every Soldier I run into, currently serving or retired! I know what a sacrifice you make to serve your country. and don't think our men and women serving get to hear it enough. so Thank You !!!!

[martin]

Yup like Jim does straight through with a Dremel 1" cutting disc, cut .098" upwards & never had one uncoil when cutting.

[JIM MARCUM]

I appreciate that very much, Todd. You can call me JIM, Mr. MARCUM, or whatever. Your porch is safe.

I think you'll love the Dremmel cut-off method. Just start a shallow cut & work it around the cable. Repeat making passes until it works it way thru the cable. When the cut is made, I lightly "debur" the end of the cable with my bench grinder. It's so easy my Mcaw could do it. I tried soldering, then a fine toothed hacksaw, and a 10" cut-off wheel on a radial arm saw only to wind up with loose cable strands. Cuz I use a mini-torch to solder FE wires & on my first tries at soldering a flex cable, it just heats up the tempered cable strands & weakens it. Actually had one twist apart in the collet.

But some swear by the solder method. To me it's just unecessary extra steps. JIM

[CatMan]

Thanks for the help! I will be doing this soon.... and my name is Todd. ( im to poor to hire a trailer inbred to pee on your porch, I'd have to do it myself) and I don't get out to California very often.( so you're safe)
I used to live in San Jose, but that was a very long time ago
Branson, Mo. has military appreciation week now and it's been great! last year Lt. Col. Oliver North was here. If you ever come for that let me know and I'll take you out to dinner!
Thanks again! for your help here, AND for your service

[JIM MARCUM]

Both of my parents were from Kansas/Mo. area, Todd. Most of the Marcums are spread around Mo.

I used to live in Santa Clara 30 years ago, right next door to San Jose.

If you ever get to San Diego drop by. Just don't pee on my porch JIM

PS: It was "Kieth" that started this thread Todd, my Limey friend (BAAAAAWAAHAHA!!!)

[ejimbo4]

Question....What if I only needed to take like a1/8" maybe 3/16 off the end? Would my bench grinder work? I only need to take off maybe a little more than the thickness of a dremel wheel....

[martin]

I fine tune the length after cutting with the Dremel on the bench grinder & also take the bur off so it leaves a bevel on the end to make going into the coupling easy.

[JIM MARCUM]

Question....What if I only needed to take like a1/8" maybe 3/16 off the end? Would my bench grinder work? I only need to take off maybe a little more than the thickness of a dremel wheel....

I've done that, but the end will get red hot when you grind it, thus taking some of the temper out of the cable strands. Just use a dremel cutoff wheel and not risk de-tempering the cable end. It only takes a few seconds more to do it right. JIM

[ejimbo4]

Thank you! A dremel it is! Glad I asked!