Groovy Cycleworks...internal cable routing

Here's a short picture vid on how to do internal cable routing in a custom bicycle frame

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• bicycle
• frame
• fabrication
• internal cable routing

[ilikebikesklube]

im assuming you silver brazed cause brass would melt the tube. what did you use to bend the tubing?

[GroovyCycleworks]

@ilikebikesklube ... Yes, 45% silver was used as it has a lower temperature and fills the space around the internal tubing well. To bend the tubing, I filled the internal with brass to support the internal wall from collapsing and used a Rigid hand held bending die. You could easily use just the pressure of your thumbs/hands as well, but the die maintains the cylindrical shape better.

[GroovyCycleworks]

Phaethon42,

Yes, you could also run the internal tubing in a curved tube by shaping it prior to advancing. You will need to run cable housing to protect the integrity of the brass inner tubing as well as to keep the cable quiet during operation.

[GroovyCycleworks]

Very true remarks, however, internal cable routing does much more; it increases the strength and fatigue resistance of the tube and allows for quiet/non-rattling of the cable run, both negative attributes of unsupported internal routing.

As for weight, you'd lose more blowing a snot rocket that what the thin brass tube weighs. Sometimes the quality and longevity of the equipment is more important than it's gravitational pull. :)

Thanks for checking in.

[taiden]

Hey, how would you suggest doing this with a TIG torch?

[GroovyCycleworks]

@taiden ...

You would need to use stainless hydraulic tubing, extend the run at least .500" past the tube, slide in a heat sink of non-ferrous material to prevent constriction, and tig around the external circumference. Then file down smooth. Good luck

[phaethon42]

Great vid, thanks! Would this work for a curved top tube? Would you be able to run the cable through the brass tube without the sheathing?

[egopower]

That's very slick, but I can't help but think unnecessary. What you've done there will certainly make it easier and faster to run new housing, but it's not that hard to fish housing through without a guide. Plus, the guide adds weight... : O

Well done though. As I said, very slick.