need ideas....clutch cable temp fix?

[k9handler]

I have a very important trip to the Nurburgring scheduled for tomorrow, and wouldn't you know it something would break the day before!
On my way home from work today my clutch cable snapped a few strands...not sure how many but at a glance it appears to be 1/4 to 1/2 of them.

I just ordered a replacement from our host in hopes to get it here this next week as I have another trip planned, but that does not help my situation for tomorrow.
I was thinking of using another small piece of cable (mountain bike brake cable) and use it to bridge the small broken area...but how would I secure it?

Or...any other ideas for a quick fix?

[Rot 911]

Hardware store should sell cable clamps. They even make really small ones. Clamp on either side of the break.

[Early_S_Man]

Smitty,

I hpoe you ordered new clevis and clip, as well!

If it is still the OEM '75 cable, and it is broken in the 'usual' spot ... right at the firewall where the Bowden tube ends ... my suggestion is to replace the entire length with a new piece of wire rope.

1. Remove cracked/frayed cable ... being especially careful with clevis and clip, as you will need to reuse them for the temp. repair!

2. Cut replacement wire rope about 6" longer than existing end-to-end measurement.

3. Cut off both ends with about 2" of cable left on, and splice at the back, first. Two clamps may just fit, side by side, but there may be too little room. Save the corrugated boot, if still usable ... for the new cable!

4. Tape the cut end you will be feeding back into Bowden and firewall tube with a layer or two of duct tape for 3" - 4" ...

5. Feed cut front end wire into Bowden tube and firewall tube with Bowden tube held straight. When in sight up at pedal cluster ... feed all extra in and pull Bowden tube back 3" - 4" and lube with moly or other grease for the exposed 4" or so.

6. Complete re-install at back. Gap at operating arm should be close to zero, and adjuster nut should be close to spliced end to give maximum room for clamp(s).

7. With all slack taken up and Bowden tube fully-seated in 'dimple' at firewall ... you will have to guesstimate required /proper length for cable and make another cut before applying clamp(s) at clutch lever. My suggestion is to cut a bit off the threaded portion of connecting piece ... so as to have minimum engagement at clevis, and maximum room for clamp(s) ...

8. Clamp at front splice and install clevis and clip.

9. Measure clutch pedal freeplay ... and hope for nominal 15 mm - 20 mm! If freeplay is excessive, adjust clamp(s) back at rear splice.

Good luck!!!

[k9handler]

I might be lucky and be able to get a replacement cable from the Porsche Zentrum tomorrow morning, but as another option I am going to stop at a hardware store in the morning and pick up some cable clamps like Kurt stated above.

This clutch cable is only a couple years old as I purchased it from our host when the last one broke (in the same spot, right at the bend of the arm). So I think my fix will work.

Tonight I modified a couple bolts from a mountain bike and used them to secure another section of cable over the break...since the cable had not broken all the way through I couldn't use the parts I wanted to.

If the cable does break all the way, I have the parts in the car and can make the repair roadside if needed.

Nurburgring or bust!

BTW....Pelican member rexav8r is here for the trip so this is why I am willing to make every effort possible.

[k9handler]

here are some pics (yes I know it's dirty)


ABOVE: These were what I wanted to use, but the cable would have to be broken all the way.


ABOVE: I modified these with a gap down the center and was able to secure the broken cable section with another piece of cable.


ABOVE: Dirty as can be the fix is in place and seems like it will hold.