rcommbikes 

We have had this original Zipp Vuka aero bar donated to us. It requires special steel ferrules for the brake housing and cables where they pass through the carbon near the brake handles. SRAM says the parts are obsolete and I have not been able to locate any. The part numbers are 11.6600.024.010-Vuka Shift 4mm Ferrules Qty 2
11.6600.025.010-Vuka Shift 5mm Ferrules Qty 2 I am including an image of the bars and the ferrules.
Does anyone know where I can get these ferrules?

Thank you in advance.

Fred

FBinNY 

Visit a bike co-op or a shop that does tons of repairs. They probably have a drawer full of a wide variety of ferrules.

Bring the bar and sample of the cable with you. Odds are you won't find an exact match, but should find one that meets the needs.

Also dsome complete cable kits come with various ferrules, 2 of which may be suited. Hopefully clear packaging will let you look before you buy.

rcommbikes 

Thanks. We do 3-4000 free repairs a year and shop manager has never seen ferrules like this.I think the thin part has to be about the diameter of a cable crimp. Large end just fits over standard cable housing. I will look at your suggestions.

rccardr 

I have a couple that might work. Stem on one pair is 4.86mm, the other is 2.4mm.

grumpus

I wonder if a good quality V-brake noodle could be cut down to do the job. Otherwise anyone with a mini lathe should be able to make a few.

Duragrouch

Noodle suggestion sounds brilliant.

Kontact

Chuck a steel barrel adjuster in the drill press and turn down the head with a file. Flip over and turn the threads down.

I made some 600EX internal lever ferrules in the same manner in about 10 minutes.

grumpus

This was going to be my suggestion before I thought of noodles, but I'd use a grinder rather than a file - you can use a lighter touch so less risk of de-chucking. Having thought of noodles (again) I think dinner today will be Chinese.

FBinNY 

FWIW this seems like a problematic design, or maybe some other parts are missing. "Ramped" cable holes like this are usually used where the enclosed cable enters, with the fulcrum (housing stop) at the other end.

A stepped ferrule like the one pictured won't sit properly. The head has no hard stop to rest squarely against, so cable tension will have it trying to slide down the ram, resisted only by the head not fitting. That will create tendency to creep, and/or a bending moment, possibly leading to a fracture. Something more like a noodle with a curve to create a fair lead seems more like what's called for.

If I were going to work to make a part, I'd start with Brass or SS fuel line tubing. Curve it for nice fair lead, and bond or silver solder an angled stop to sit against the bar, (picture the structures where tunnels ramp down into the earth), then devise a ferrule or adaptor to transition from the part to the housing.

I'd provide a sketch, but don't know how to upload it. However if the OP wants to see what I'm describing, he can PM me with his email address and I'll send something along.

Kontact

You're aware these go way inside the bars up at the end where the brake levers go? They can't be curved because they go straight into a straight hole.

FBinNY 

Yes, I'm aware. The curve I'm speaking of is at the entry area only, and in a plane normal to the bar. If you sketch a side view you'll see the issue I described.

As I said, the maker didn't build in a proper seat for the intended ferrule. IMO, it's either poor design, or poor execution, but what's done is done, and the OP can either try to improve it, or leave it as is.

BTW - I'd love to see what's inside and how the maker provided for the 90 degree turn from cross piece to lever.

Kontact

Huh? There is no 90 degree turn. The cable goes straight into the front of the lever, straight through the narrow end of the ferrule and straight into the housing. The only bend is the housing curving though the inside of the bar to the exits.

Again, the ferrules are part of the brake lever, not the entry to the bar. Have you seen one of these bars, or looked at pictures of the lever fronts?

FBinNY 

Mia culpa. No I haven't seen the bars in the flesh. I saw the image on a cell phone, so obviously, and took the slots on the bottom as the cable exits.

So, feel free to disregard my post.

Kontact

Those are the housing exits. That is what I pointed out to you, twice. The ferrules go nowhere close to them.