Retainer clip for Tommaselli Boot

[blackcat]

Anyone have any idea where to find one of these clips?  Evidently they are no longer being made because the new throttles do not have the holes for the clip.

[guzzisteve]

I have made a few w/stiff wire same size.

[blackcat]

I have made a few w/stiff wire same size.

Steve, or anyone can, you post a photo of what that clip looks like as I have no memory of the part. Last time I so one up close was probably 15 years ago. Thanks.

[moto]

Steve, or anyone can, you post a photo of what that clip looks like as I have no memory of the part. Last time I so one up close was probably 15 years ago. Thanks.

The original is spring steel, 1.2mm (about 0.05") diameter, nearly an inch from side to side:





Moto

[blackcat]

The original is spring steel, 1.2mm (about 0.05") diameter, nearly an inch from side to side:





Moto

Thanks!

[guzzisteve]

That's it I thought it had a spring loop in it. I didn't make a loop.

[lazlokovacs]

I have long wondered how on earth those boots were supposed to stay on!

mine usually hangs about halfway down my throttle cables after it gives the cable tie the slip

[blackcat]

I have long wondered how on earth those boots were supposed to stay on!

mine usually hangs about halfway down my throttle cables after it gives the cable tie the slip

Yeah, they do that except when the boot is new. I wonder why they stopped making this device and the holes for the newer throttles? Could it possibly cost that much money?

[guzzisteve]

I think the wire hold the cables in, I always put the little tang on rubber flap in between the two halves then tighten the screws.

[moto]

I think the wire hold the cables in, I always put the little tang on rubber flap in between the two halves then tighten the screws.

That's right. I just had mine apart again. The wire fits into grooves on the ferrules of the cables, holding them in the correct positions. The little tang on the rubber flap is clamped between the two halves of the throttle housing, to hold the rubber boot in position. A subtle design, for sure.

Edit: The wire also helps hold the boot.

[wirespokes]

Could someone post pix of this? I've had two of these throttles and neither had/has a clip.

[Kiwi_Roy]

Thanks!

Try making that from a stainless bicycle spoke, your local bicycle dealer will give you an old wheel if you ask nicely, the spokes are real handy.

[moto]

Could someone post pix of this? I've had two of these throttles and neither had/has a clip.

Also see my earlier picture of the clip lying on a piece of graph paper, above.

[moto]

How to bend loops into wire:

[Antietam Classic Cycle]

How to bend loops into wire:

To make loops, I've always bent it around a rod, bolt, pin, etc. that's smaller than the desired diameter of the loop.

[moto]

To make loops, I've always bent it around a rod, bolt, pin, etc. that's smaller than the desired diameter of the loop.

That's how I used to do it, but I've found this author's method works better for me.

[Antietam Classic Cycle]

That's how I used to do it, but I've found this author's method works better for me.

You'd need to use pliers with very narrow jaws (needle nose?) to bend a loop as small as the one on the Tommaselli clip.

[wirespokes]

Thanks Moto! 

I'm with Charlie on making the loop. That's gotta be the easiest and cleanest way to get the job done. I've made springs on the lathe by wrapping wire around a mandrel (rod). Same thing essentially. Once you have the loop, making the two bends on each side are simple.

[moto]

Well, gentlemen, it would be easy to try bending a loop the other way, right? 

Moto

[Antietam Classic Cycle]

Well, gentlemen, it would be easy to try bending a loop the other way, right? 

Moto

I have tried it with pliers, that's why I went to bending them around a rod.

[cliffrod]

Smooth jaw pliers (actually smooth or with metal covers over teeth, which is fiddly on small items like this) are better to use if you're not using a rod or mandrel.  Teeth will often scar the wire and create a stress riser at the same time the wire is being work-hardened when you bend it.  Not cool X2.   These parts will rust, break or both

Some needle nose pliers have a smooth area closer to the hinge.  Other pliers made specifically for such work are already smooth, whether the jaws are flat or round.  A finishing nail or few in a piece of 2x4 that's screwed to bench or clamped in vise makes a simple jig that works well.  Easy to make a jig like this with nails that can be added once a preceding bend is completed.  Then the parts you make will hopefully match. 

Edit- smooth jaw wire bending pliers from my toolbox.  The round ones in the foreground work really well for small loop work-

[moto]

I have tried it with pliers, that's why I went to bending them around a rod.

OK. As I beat my retreat, let me point out that my recommended method is more specific than just to use pliers.  Just saying.

Moto

[blackcat]

Thanks guys, I'm going to try it both ways and see what happens as I need two of those clips.

[Frenchfrog]

This guy might just have a source...worth an email https://www.ducatipaddy.com/page25.html

[Antietam Classic Cycle]

Paul Montgomery has the boot, maybe he knows of a source for the clip?
http://guzzino.com/tothcabo.html

[wirespokes]

I currently have two of these throttles and neither has the clip. The boot doesn't have holes either. Are you saying the throttle possibly won't have holes for the clip? Obviously I haven't pulled the boot down for a look.

[moto]

I currently have two of these throttles and neither has the clip. The boot doesn't have holes either. Are you saying the throttle possibly won't have holes for the clip? Obviously I haven't pulled the boot down for a look.

Perhaps you should look. If your boot has a locating tab you'll need to loosen the clamping bolts on the throttle housing first.

If you find no holes, the next question is what retains the throttle cable ends (ferrules) in the new design. This would be valuable information for others.

Moto

[Tom H]

Nothing. Just cable tension and the rubber boot. With the cable adjusted with a little slack, the cable will slide in and out of the housing, but not fall out.

Tom

[moto]

Nothing. Just cable tension and the rubber boot. With the cable adjusted with a little slack, the cable will slide in and out of the housing, but not fall out.

Tom

 

[Antietam Classic Cycle]

Made one this evening, works but is a little bit wider than original. I'll make another one just a smidge narrower.