Master How To Cut Bike Cable Housing Perfectly

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Master How To Cut Bike Cable Housing Perfectly

Do you need to cut bike cable housing? Yes, you do if you are replacing old cables, installing new ones, or just need to fix a damaged section. Cutting bike cable housing cleanly is a key step in keeping your bike working right. It helps your brakes and gears work smoothly. A bad cut can cause problems. This article will show you how to cut bike cable housing the right way using the right tools.

Why Good Cuts Matter

Cutting bicycle cables and their housing seems simple. But a clean, straight cut makes a big difference. The housing protects the inner cable. It gives the cable a smooth path to slide inside.

When you squeeze a brake lever or push a gear shifter, the inner cable moves inside the housing. If the housing end is not cut well, it can cause trouble.

A bad cut can pinch the housing end. This closes the hole where the cable runs. The cable cannot move freely. This makes your brakes feel stiff. It makes your gear shifts slow or sticky.

A bad cut can also make the housing wire coil poke out. This happens often with brake cable housing. It has wires that wrap around. A squashed end or poking wires can damage the cable. They can also stop the cable from sitting right in the ferrule or frame stops.

Cutting bike cable housing correctly is key for good performance. It helps your bike feel safe and responsive.

Different Types of Cable Housing

Not all bike cable housing is the same. There are two main types:

• Brake Cable Housing: This housing is built strong. It has a thick layer of wire wrapped in a spiral shape under the plastic cover. This wire makes it strong against squeezing forces. When you pull a brake lever hard, the housing tries to compress. The spiral wire stops this. A bad cut can crush this spiral wire. This makes the housing shorter under force. Your brakes can feel spongy or delayed.
• Shifter Cable Housing: This housing needs to be stiff and not stretch. It has wires that run straight along the housing, parallel to the cable. These are called linear strands. There can be many thin wires running this way. This design resists stretching. Stretching would mess up gear indexing. A bad cut can bend or misalign these straight wires. This adds friction for the shifting cable. Shifting can become hard or inaccurate.

You need to know which type you are cutting. While the cutting process is similar, checking the end is very important for both types. Especially make sure the straight wires in shifter cable housing are clear. For brake cable housing, check the spiral wire isn’t squashed.

The Best Tool for the Job

Using the right tool is the most important step in cutting bike cable housing well. You need special bike cable cutters.

Can you use normal wire cutters or pliers? No. Please do not use them.

Here is what happens if you use the wrong tool:

• Normal Pliers/Cutters: These tools are made to cut things straight through. Bike housing is not a solid bar. It has plastic, wire layers, and a liner. Normal cutters will crush the housing. They will not give a clean cut. They will leave a messy, squashed end. This is the fastest way to ruin housing.
• Side Cutters: These are a bit better than pliers but still bad. They often squeeze the end and leave a rough edge. They will likely fray the inner plastic liner and wires.

What makes bike cable cutters special? They have shaped jaws. These jaws support the round shape of the housing as they cut. They shear through the housing, rather than just crushing it. A good pair will cut through the plastic outer layer, the wire reinforcement, and the inner plastic liner smoothly. They leave a clean, round opening. This is key for the cable to move freely.

Think of it like cutting bread. A sharp bread knife cuts cleanly. A dull knife just squashes the bread. Bike cable cutters are the sharp bread knife for your housing.

Choosing the best bicycle cable cutter is worth it. A good quality cutter will last a long time. It will make clean cuts every time. Cheap cutters can become dull quickly. They may start crushing the housing after only a few cuts.

Look for cutters with:

• Sharp, hardened steel jaws.
• Jaws shaped to support the round housing.
• Comfortable handles for a strong grip.

Good bike cable cutters are the number one secret to mastering how to cut bike cable housing perfectly.

Other Helpful Tools

Besides your bike cable cutters, you will need a few other simple tools:

• A Pick or Awl: This is a small, pointy tool. After cutting, the inner liner or wires might be slightly closed off. The pick or awl helps open up the end again. You gently push it into the end of the housing to make the hole perfectly round and clear.
• A Small File or Grinder: Sometimes, even with good cutters, there might be a tiny sharp edge or a bit of wire sticking out. A small file lets you smooth this down. For brake housing, you might file the outer wire ends flat if needed. A mini-grinder (like a Dremel tool) can also work but be careful not to melt the housing plastic. A file is usually safer and easier for most people.
• Safety Glasses: Always wear safety glasses when cutting housing or filing metal. Small pieces can fly off. Protecting your eyes is very important.
• Measuring Tape or Ruler: You need to measure the old housing length or the needed new length accurately.
• Marker or Pen: To mark where to cut on the housing.

Gathering these simple tools with your bike cable cutters will make the job much easier and give you better results.

Steps for Cutting Cable Housing

Now, let’s go through the steps to cut your bike cable housing perfectly. This process applies to both brake cable housing and shifter cable housing. The goal is a clean, open end ready for cable housing ferrules and installing bike cables.

h4 Measuring the Housing

The first step is to know how long the new piece of housing needs to be.

• Replacing Old Housing: The easiest way is to use the old piece as a guide. Lay the old housing straight. Lay the new housing next to it. Make sure they are flat and not stretched or bent. Mark the new housing at the exact same length as the old one.
• New Install or Different Routing: If you are changing your cable routing or doing a new build, you need to measure on the bike. Route the housing path from the lever/shifter to the frame stop or component (brake caliper, derailleur). Follow the path the housing will take. Allow smooth curves, not tight bends. Tight bends make the cable rub and work poorly. Cut the housing a bit long at first. You can always cut more off if needed. You cannot add length back.

Use your marker to make a clear line where you need to cut.

h4 Positioning the Housing in the Cutter

Get your bike cable cutters ready. Open the jaws wide enough to fit the housing. Place the housing into the cutting jaws. Line up the mark you made on the housing with the cutting edge of the jaws.

Make sure the housing sits squarely in the jaws. The housing should be at a right angle (90 degrees) to the cutter jaws. Do not hold the housing at an angle. This will result in a crooked cut.

Get a firm grip on the housing near the cut line. This stops it from moving as you cut.

h4 Making the Cut

This is where your good bike cable cutters shine. Squeeze the handles of the cutters together firmly and smoothly. Use steady pressure. The cutters should slice through the housing with a clean action.

Do not try to cut too fast or in steps. One firm squeeze is best.

As you squeeze, the jaws should support the housing shape. You should feel it cut through the different layers.

Listen for the sound. A good cut makes a sharp snip. A bad cut might sound like a crunch or tear.

After you make the cut, open the cutter jaws. Take the housing out.

h4 Checking the Cut End

Look closely at the end you just cut. This is a very important step.

A perfect cut will have:

• A clean, straight edge.
• An opening that is perfectly round.
• No squashed plastic.
• No wires poking out or bent inward.

What if it’s not perfect? Even with good cutters, you might need to clean it up. This is normal.

h4 Cleaning Up the End

This is where your pick/awl and file come in.

• Using the Pick/Awl: Look into the cut end. Is the inner plastic liner pinched shut a little? Are any wires blocking the hole? Take your pick or awl. Gently push the point into the end of the housing. Twist it around a little. This will open up the inner liner and clear any debris. Be careful not to force it and damage the housing further down. You just want to make the opening round and clear for the cable to pass through easily.
• Using the File: Feel the outside edge of the cut. Are there any sharp plastic burrs? Are there any bits of wire sticking out? Use your small file. Gently file away any sharp edges or bits of wire. File flat across the end. Make sure the end surface is flat and clean. Be extra careful when filing brake cable housing ends to make sure the spiral wire ends are flat and do not catch on anything.

Take your time with this step. A clean, open end is crucial for smooth cable movement and helps prevent cable fraying when you push the cable through.

h4 Adding Ferrules

Once the end is cut cleanly and the opening is clear, you need to add a ferrule.

Cable housing ferrules are small metal or plastic caps. They fit over the end of the housing. Ferrules do several important jobs:

• They protect the cut end of the housing.
• They keep the housing wires from coming apart. This helps prevent cable fraying at the end.
• They provide a smooth, defined end for the housing to sit correctly in frame stops, levers, and components.

Ferrules are needed wherever housing ends at a stop or component.

Make sure you use the right type of ferrule for the housing:

• Brake Ferrules: Usually 5mm in diameter. They are often metal, sometimes plastic with a metal liner. They need to be strong as brake housing is under high compression.
• Shifter Ferrules: Usually 4mm in diameter. Often plastic, sometimes metal. Some have special extended tips (nosed ferrules) for better sealing or fit in certain shifters/frame stops.

Slide the correct ferrule onto the clean, cut end of the housing. Push it on firmly. The ferrule should sit flat against the cut end. If the cut was not straight, the ferrule will not sit flat. This is another sign of a bad cut.

Adding cable housing ferrules is the final step in preparing your housing piece after trimming bike housing.

Specific Tips for Different Housing Types

While the basic steps are the same, keep these points in mind for each type:

h5 Brake Cable Housing

• It is thicker and harder to cut than shifter housing. Make sure your bike cable cutters are strong enough.
• Pay close attention to the spiral wire layer. A bad cut will crush this layer. Use your pick or awl to open it up carefully.
• File the end flat to ensure the spiral wire ends are neat.
• Always use strong, usually metal, 5mm cable housing ferrules on brake housing ends.

h5 Shifter Cable Housing

• It might seem easier to cut, but the linear wires must not be bent or blocked.
• Use the pick or awl to ensure the inner liner and linear wires are completely clear and the inner hole is round.
• Be careful not to melt the plastic inner liner if using a grinder to smooth the end. Filing is safer.
• Use 4mm cable housing ferrules. If your system uses them, use nosed ferrules in shifters or frame stops that are designed for them.

Following these specific tips after trimming bike housing helps ensure the best performance for each system.

Avoiding Common Mistakes

Knowing how to cut bike cable housing includes knowing what can go wrong and how to stop it.

• Mistake 1: Using the Wrong Tool.
  • Problem: Squashed ends, frayed wires, housing won’t fit ferrules or frame stops.
  • Fix: Always use proper bike cable cutters. Do not try to use pliers or wire cutters. Invest in a good pair; they will save you trouble and money in the long run. They are the best bicycle cable cutter for this job.
• Mistake 2: Not Cleaning the End.
  • Problem: Inner liner pinched, wires blocking the path. Cable catches, shifting or braking is stiff. Cable gets damaged.
  • Fix: Always use a pick or awl to open up the inner liner right after cutting. Check that the inner hole is perfectly round and clear.
• Mistake 3: Not Filing or Smoothing the End.
  • Problem: Sharp edges on plastic or wire snag the cable or damage ferrules/frame stops.
  • Fix: Gently file or smooth the cut end flat. Remove any burrs or sharp wire pieces.
• Mistake 4: Cutting the Wrong Length.
  • Problem: Housing is too short (tight bends, poor performance) or too long (messy look, can catch on things).
  • Fix: Measure carefully. Use the old housing if possible. If not, route the new housing allowing smooth curves and mark it. Cut a little long if unsure; you can always shorten it.
• Mistake 5: Not Using Ferrules.
  • Problem: Housing ends fray and fall apart, wires poke out, housing doesn’t sit correctly in stops, poor performance, damages frame stops.
  • Fix: Always install cable housing ferrules on every end that goes into a stop or component. Use the correct size (4mm for shifter, 5mm for brake).

By avoiding these common errors, you greatly improve your chances of cutting bike cable housing perfectly the first time. This helps prevent cable fraying and ensures smooth system function.

What Comes After Cutting?

Once you have cut your housing pieces correctly and added the ferrules, the next step is installing bike cables.

The process involves:

1. Threading the Cable: Push the new inner cable through the lever (shifter or brake) first. Make sure the cable head sits correctly in its spot.
2. Inserting into Housing: Feed the cable through each piece of correctly cut housing. It should slide freely with very little resistance. If it snags, check your housing ends again. Maybe the inner liner is not fully open.
3. Routing the Housing: Place the housing pieces into the frame stops. Make sure the ferrules sit correctly and flat against the stops.
4. Threading Through Component: Feed the cable through the derailleur or brake caliper.
5. Securing the Cable: Pull the cable tight and secure it with the binder bolt on the component.
6. Adjusting: Adjust the gears or brakes for proper function.
7. Final Trim: Trim the excess inner cable length (leaving enough to grab later for adjustments) and crimp an end cap on it to prevent cable fraying.

Properly cut housing makes installing bike cables much easier and smoother. It also means you are less likely to need repairing bike cable housing or dealing with poor performance later.

Maintaining Your Cuts and Housing

Good installation starts with good cuts. If your housing is cut cleanly and ferrules are installed correctly, it helps protect the system.

• Check your housing ends sometimes. Make sure the ferrules are still seated right.
• Look for any signs of wear or damage near the ends or along the housing path.
• If you see damaged housing, you might need repairing bike cable housing. This usually means replacing the damaged section. Cutting the new piece correctly is vital here.

Using the best bicycle cable cutter and following the steps helps your cables and housing last longer and work better. It reduces friction and makes your bike’s controls feel crisp and accurate.

Why Invest in the Best Bicycle Cable Cutter?

You might think a cheap pair of cutters is fine for cutting bicycle cables once in a while. But a good quality pair of bike cable cutters is a worthy investment for any cyclist who does their own bike maintenance.

• Better Performance: A good cutter gives clean cuts every time. This means smoother braking and shifting. It directly affects how your bike rides.
• Saves Time and Frustration: Trying to fix a bad cut or dealing with cables that don’t move freely is annoying. A good cutter gets it right the first time.
• Prevents Damage: Bad cuts can damage the inner cable. They can also damage the frame’s cable stops or the components (shifters, derailleurs, brakes) where the housing seats.
• Durability: Quality tools last. A good pair of cutters will stay sharp and effective for many cable replacements.
• Versatility: The best bicycle cable cutter will handle both brake cable housing and shifter cable housing equally well. They can also cut the inner cables cleanly, helping prevent cable fraying at the cable end before you crimp an end cap on.

Think of it as a tool that improves your bike’s function and prevents future problems. For anyone serious about bike repair, a quality pair of bike cable cutters is a must-have tool.

Comprehending the Impact of a Clean Cut

Let’s think about how a perfectly cut piece of housing works compared to a badly cut one.

Imagine pushing a piece of string through a straw.
* If the straw end is cut straight and open, the string slides through easily. This is like a good housing cut. The cable moves freely.
* If the straw end is squashed shut or has plastic bits blocking it, the string will catch and be hard to push. This is like a bad housing cut. The cable drags, making shifting or braking hard.

Now add the cable housing ferrules. They act like a clean entry point into the straw, guiding the string smoothly. Without them, the messy straw end might catch the string or just look bad.

For brake cable housing, a bad cut that crushes the wire coil means the housing gets shorter when you brake hard. This takes up some of the cable pull. Your brake lever feels mushy, and the brakes don’t bite as hard.

For shifter cable housing, a bad cut bending the linear wires adds friction. The derailleur might not move enough with each click of the shifter. This leads to missed shifts or chain rub.

Cutting bike cable housing correctly is not just about making a cut. It’s about preparing the housing to be a smooth tunnel for the cable. It’s a small step that has a big impact on your bike’s performance and feel. It’s part of mastering installing bike cables and avoiding the need for constant repairing bike cable housing.

A Step-by-Step Summary Table

Here is a quick look at the main steps for cutting bike cable housing:

Step	Action	Why It Matters	Tools Used
Measure	Determine correct housing length. Mark cut point.	Ensures proper fit and smooth routing.	Measuring tape/ruler, marker
Position	Place housing in bike cable cutters, align mark.	Sets up a straight, clean cut.	Bike cable cutters
Cut	Squeeze cutters firmly and smoothly.	Makes a clean cut through all layers.	Bike cable cutters, Safety glasses
Check End	Inspect cut end closely.	Finds any issues like squashing or wires poking out.	Eyes
Clean End	Use pick/awl to open inner liner. File rough edges.	Ensures inner path is clear, removes snags, helps prevent cable fraying.	Pick/awl, File/grinder, Safety glasses
Add Ferrule	Slide correct size cable housing ferrule onto end.	Protects end, keeps wires together, provides clean seat in stops.	Cable housing ferrules (4mm or 5mm)

Following these steps helps you achieve a perfect cut every time.

Repairing Bike Cable Housing

Sometimes, you don’t need to replace all the housing. Maybe just one section is damaged, cracked, or kinked. In this case, you are repairing bike cable housing.

This involves:

1. Finding the bad section.
2. Carefully removing only that section. You might need to disconnect the cable from one end (like the derailleur or brake).
3. Cutting a new piece of housing to the exact same length as the damaged section you removed. Use the damaged piece as a template for measurement, just like replacing a whole cable run.
4. Cutting the ends of the new piece perfectly using your bike cable cutters and cleaning them with the pick/awl and file.
5. Adding cable housing ferrules to both ends of the new piece.
6. Putting the new piece back into the cable run. The cable should slide through smoothly.
7. Reconnecting the cable to the component and adjusting as needed.

Even for repairing bike cable housing, the cutting steps are key. A bad cut on the small replacement piece will still cause problems.

Trimming Bike Housing

The phrase “trimming bike housing” is just another way of saying cutting it. You trim it to the right length during installation or repair.

Whether you call it cutting or trimming, the goal is the same: a perfect end. The methods and tools discussed here are how you achieve that perfect trim.

When you are setting up new cables, you often trim off excess length after routing to get the neatest path. Again, make that final trim a good one!

Frequently Asked Questions

h4 What size cable housing ferrules do I need?

You need 4mm ferrules for shifter cable housing and 5mm ferrules for brake cable housing. Make sure they match the housing type you are using.

h4 Can I use brake housing for my shifters?

No. They are built differently. Brake housing compresses (spiral wire) which is bad for shifting accuracy. Shifter housing stretches (linear wires) which is bad for braking force. Always use the correct type: brake housing for brakes, shifter housing for shifters.

h4 How do I know if my cut was bad?

Signs of a bad cut include: squashed or non-round housing end, wires poking out, cable catches when pushed through, ferrules don’t sit flat on the end, or your brakes/gears feel stiff or work poorly after installation.

h4 My cable is fraying inside the housing. Why?

This can happen for several reasons. One reason could be a poorly cut housing end or missing ferrule that damaged the cable over time. Other reasons include worn-out housing liner, rust, or a damaged inner cable itself. Proper cutting and installation using cable housing ferrules helps prevent cable fraying that starts at the housing ends.

h4 How can I make my housing cuts last?

Using high-quality bike cable cutters and always cleaning the ends with a pick/awl and file ensures a good start. Properly installed cable housing ferrules protect the ends. Keep your bike clean, as dirt and water can cause problems inside the housing over time, affecting cable movement and potentially leading to housing damage that needs repairing bike cable housing.

Cutting bike cable housing is a fundamental skill for bike maintenance. By using the right bike cable cutters, taking your time to measure, cut, and clean each end, and adding the correct cable housing ferrules, you will ensure your brake cable housing and shifter cable housing are perfectly prepared. This leads to smooth-working brakes and gears, making your riding experience much better. Mastering how to cut bike cable housing perfectly is a simple task that yields big rewards in bike performance and longevity.