masi61

I need suggestions on a slick way to remove just a very small amount of clear outer housing on Jagwire housing that is about 4.6 mm outer diameter. The derailleur housing is Jagwire woven stainless steel look, gold color with a glossy clear cover. I’m needing to extend them a short length due to miscalculation. I did a nice tape job on my bars and the housing exits near the stem and plunges down to the down tube braze-on adjuster. The regular ferrules fit fine but i’m trying to use a double ended ferrule in order to gain about 3” extra. I found some nice Jagwire ones at the bike shop for $2 each that should work but don’t. The inner diameter for the double ended ferrule is ~4.5mm, 0.1mm too tight.

Is there any handy way to ream the ferrule to gain the clearance I need? Or, what would be the most efficient way to strip away some of the clear outer cover to create a perfect fit?
I know i’m over thinking this but sometimes it’s the little annoying things like this that really mess with your mind!!
Thanks for any help.

tyrion

Sandpaper? Wrap it around the end of the housing and twist twist twist.

masi61

Oh yeah, well duh, - I was thinking I needed a blade. Will use some sandpaper, thanks...

SethAZ 

With a pair of reading glasses (it happens to everyone eventually...) and an Xacto knife that would take like 3 minutes. But yeah, sandpaper should work too.

Jeff Wills

Ditto the sandpaper. I've done it a couple times to clean up the plastic when it expands from heat created when I grind the end of the housing flat.

Aubergine 

Yeah, I use a sharp knife to pare off tiny snips of the plastic.

maddog34

razor knife with a fresh blade.

bikeme

If you go with a blade, use it 90 degrees to the housing to scrap vs slice off the excess. trying to slice it off will be a disaster (I've done this with other items)

dsbrantjr

You might be able to heat the plastic cover with something like a hairdryer, enough to insert it into the ferrule. Or try dipping into alcohol or hot soapy water and just shoving it in. If you only have 0.1mm interference it might go right in.

Davet

Isn’t there a step-down 5mm~4mm ferrule?

Jon T

.1mm equates to .004". A piece of notebook paper is .003" thick. I think the sand paper will get rid of your excess thickness in about 3 heart beats.
Jon

masi61

https://flic.kr/p/22ePwyJ

Thinning the outer housing with a diamond Swiss file had been my plan. Problem is, the weave or mesh is just below the clear outer cover and it appears quite delicate. So reaming out the double ended ferrule (and leaving the housing alone) seemed the more satisfying course of action. I used a 3/16” reamer at low speed in my drill press with some tap oil for lubrication & it worked great!

https://flic.kr/p/21cKAfm

PS: I’m using Flick’r for my images which does appear to work to create a link. But my desire is for the image to immediately pop up without clicking the link. Can someone tell me how to use Flick’r more effectively?

masi61

https://flic.kr/p/CDtMHM

Here you get a view of last week’s fresh tape job with the too short derailleur compressionless housing...

masi61

“Extenders” in place on compressionless housing: https://flic.kr/p/22i4vae

fietsbob

Or... put an oversize brass ferrule on, and squeeze it around the housing..