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Antiem: "Fun" LOL. So I'm finding out.*SNIP*N3303j: You're solution definitely appeals to my DIY side, because I now have two good cables which are too long. But I was told that silver solder doesn't fill gaps and I don't have silver solder or flux. You think that copper pipe solder might work? I've found a Utube video which describes shortening a cable https://www.youtube.com/watch?v=WZ21dGNIbJwand another which talks about making a die to square up the cable end. https://www.youtube.com/watch?v=z82RtQZGZ9c
Properly cleaned and fluxed silver solder will fill the gaps as long as you don't overheat the joint.But filling the gaps isn't necessary. It's just important that all the wires are joined to each other by the silver bonding agent.I wouldn't trust lead plumber's solder to bond well to the steel wire.No reason those video processes wouldn't work. That's probably how it's done in the factory (but with much neater dies).But my method is sufficient and quick.I measure the square with a micrometer. I measure the round with a micrometer. I compute the difference divided by 2. That is the amount to file off each side to make the round into a square.I have a good vise with ground jaws. I grab the cable in the vise and file the first flat. Watch to keep it even width (so that it is even depth). Measure it and file until the first flat is parallel with the unworked side of the cable and is the correct depth (it's actually easier than it sounds, just don't rush.Never shortened these type of cables, but, something worth considering is finding a brass button from a ball point pen, flatten it into a square shape, and see if it fits the back of the gage. If it does, maybe solder it to the inner tach cable. Almost free to try it.....(Guzzi content!)When done grab the cable in the vise so the first flat is against the stationary jaw. Now file the second flat parallel to the top of the vise. This establishes the 90 degree form. Use the two finished flats fastened against the fixed jaw of the vise to set up for filing side 3 and 4. Takes less time than watching the videos.
Don't overthink the flux. I use the same little tube for everything I solder.