Been doing some tweaking on the Texas Scorcher. I kept the janky levers that came with it to save a buck. Problem is, with this lever, when properly set, the clutch cable adjuster has to be screwed pretty far out. This really bothers me.
The correct solution would have been to cut a little off of this cable end, and then re-cast new solder around the cut end. This would have been pretty easy. The fitment of this cable end is not critical. The casting could have been crude, and then shaped with a Dremel. Unfortunately, I didn't think of this until I had already done the following more complicated fix:
Instead of shortening the cable, I lengthened the sheath. Surely this has been done countless times by others. Here's how I did it using the Fred Flintstone tool kit:
I salvaged this elbow from an old clutch cable, and cut it, saving the small piece that fits into the case cover.
Chucked that cut piece in a big drill motor.
And put the drill motor in my vice. This held the piece-o'-elbow steady while I drilled in to the end using a second drill motor. The drilled-out end will accept the elbow from my working cable.
Next, I chucked the piece into a tap holder. This allowed me to hold the piece while I squared and shortened it a littler using a bench grinder.
Cut a slot in it.
And slipped it over the cable. The working elbow turned out to be a nice press fit in the bit-o'-elbow. I was going to slip a piece of heat-shrink over it, but it looks pretty good as is.
Much better. Not the easiest way, shortening the cable probably would have been faster, but the silver lining is that what I did is reversible.
