DIY Homebuilt Clutch Cable

[smutts]

One of the irritations of the standard Mk2 golf GTD is the clutch cable.
Due to the positioning of the intercooler, the clutch cable needs a bend in it to clear it.
If a manual adjusting type was available, no problem. Unfortunately the only offering is that wretched self abusing thingy. Which misbehaves if ignored, misbehaves if lubricated, randomly adjusts the bite point, leaves the pedal on the floor or leaves the clutch slipping, and at times I think Arthur Harris had the right idea.

So I can assemble one myself, but the question is what sort of methods are most reliable to clamp, braze, glue, cotter or wedge the end of the cable together? Or do I need to go to a yacht rigger?

Any ideas?

[maxfax]

I installed a MK1 Rabbit cable on a MK2 jetta years back..   I just don;t remeber what exactly had to be done to make it work...

[fatmobile]

There's a manual cable for the MK2.
 The early ones had manual cables, not sure when they stopped.

[smutts]

Due to the positioning of the intercooler, the clutch cable needs a bend in it to clear it.

Yes, there are manual adjusters that can be bodged in, Thats what the Red GTD is using at the moment, but there is also fifty yards of baling twine tied at strategic points about the engine bay to persuade it to clear the intercooler, this also makes the cable a smidge too short. It works, but just looks horrible. That is why I want to Frankenstein something better in there. The question really is how to attach a steel cable to a lump of metal and it not snapping after a dozen years of being stamped on.

Any ideas?

[macka]

 I know if you go to a breakers and stroll around, you may find one that fits the bill. I'd suggest looking at at the Ford or Mercedes Lorries.

[truckinwagen]

morse control cables come in whatever length you would need, and have a plethora of ends to attach to the pedal and transmission ends, as well as a bunch of cable stop options.

morse cables can be purchased at lots of marine supply stores, as well as many on line buggy suppliers like dansperformanceparts.com

-Owen

[macka]

     1H1 721 335 AB  compliments of vince walden its a mK3 manual cable

[jtanguay]

Due to the positioning of the intercooler, the clutch cable needs a bend in it to clear it.

Yes, there are manual adjusters that can be bodged in, Thats what the Red GTD is using at the moment, but there is also fifty yards of baling twine tied at strategic points about the engine bay to persuade it to clear the intercooler, this also makes the cable a smidge too short. It works, but just looks horrible. That is why I want to Frankenstein something better in there. The question really is how to attach a steel cable to a lump of metal and it not snapping after a dozen years of being stamped on.

Any ideas?

use the joiner pieces for aircraft cable. those things aren't going anywhere!  i can just see it now.. under your hood with aircraft cable, and some pulleys.  that would be pimpin' 

[LoneWolf]

Dude, find a motor factors that deals with QH parts (Quinten Hazel) they do a manual clutch cable for the mk2. infact, i think ive got one in my shed that i got to use on my GTD but CBA to fit