Flex cable question---how is a .187 made?

[tlandauer]

I understand how a common .150 is made. The cable simply "glides" into the stub shaft which has a bore the size of .150, then is either soldered or epoxied with thread locker. The diameter of the shaft itself is bigger at 3/16" which is .187.
Now if the cable is .187, something has to give, do they grind down somewhat the cable for it to go into the stub shaft? I don't run this size but from photos I can see the cable is as thick as the sub shaft. Any enlightenment will be greatly appreciated!

[martin]

You take a .187" flex & unravel the outer winding to the depth of the hole in the stub & cut off this outer wind off, that leaves a .150 inner core on the flex. The stub is drilled .150" & the .150" cable goes into the stub hole, the .187" part of the flex butts to the front of the stub. Its then brazed in with braze down inside the hole & also brazed in the butt area + around 1/4" further along the flex where it butts the stub then the outer braze is cleaned up in the lathe. I also braze them whilst held between the 2 lathe chucks so their nice & true.

[tlandauer]

Thanks for the enlightenment! Next stupid question: since it is "stripped down to .150" where it mates to the stub shaft, what is really the advantage of a .187 cable? I know the rest of the cable is thicker, but the stripped down area is after all a .150 sized cable although with brazing it is strong. The torque that the connection point must bear has the same diameter plus the
"stripped" cable lost one winding---by the way, any consideration on the direction of the winding? the outer winding indicates the rotation of the cable so the inner one must be the opposite direction. My guess is that with brazing it is strong enough that it doesn't matter.
Sorry about the long winded rant---I want to learn and there is no better place than here at the Forum.
Cheers,
Tim

[Basstronics]

The face where it goes from .150 to .187 is also silver soldered and beyond that.

[martin]

The face where it goes from .150 to .187 is also silver soldered and beyond that.

Quote in my discription above, Also brazed in the butt area + around 1/4" further along the flex where it butts the stub. Martin.

[tlandauer]

Thanks so much, guys!