Clutch Cable Fraying

[Dwleo]

Here I post again.
I noticed my clutch cable is fraying on the quadrant arm.
I haven't even gone karting yet, just been and out of the garage a dozen times. The quadrant doesn't seem to line up with the adjuster mounted on the footbox.
I cannot see an easy way to realign them.
Ideas?

[edwardb]

Same as I posted in the other forum: Just an observation FWIW (maybe not too much) from someone who hasn't used that modified quadrant before. The edges of those cut pieces look really sharp. I've observed those kind of parts from FF, whether laser or plasma cut (not sure in this case), while extremely precise have very sharp edges. Maybe it would help to have a slightly rounded or chamfered edge on each side where the cable is being guided.

[CraigS]

Long time ago someone recommended this technique. Remove the cable and adjuster. Find a socket that fits nicely in the sleeve the adjuster fit in. Add an extension to the socket. Push the end of the extension to 'adjust' the sleeve so the cable aims at the quadrant more accurately.

[Dwleo]

Long time ago someone recommended this technique. Remove the cable and adjuster. Find a socket that fits nicely in the sleeve the adjuster fit in. Add an extension to the socket. Push the end of the extension to 'adjust' the sleeve so the cable aims at the quadrant more accurately.

The problem is that the angle is the opposite. Can't bend the 'hole' for that angle.

[GFX2043mtu]

Chamfer the plates as Edward said. Heck I polished the charmers on mine and aligned the cable so it falls directly in the middle. The edges are far to sharp and will wear the cable out as you are seeing.

[JIMOCO]

There is another post where I am asking for recommendations regarding clutch cables. My original cable failed at the exact same spot. Since I am working on a completed car it is difficult to chamfer the edges. I took a rat tail file, put in in my drill and came through the firewall and smoothed off the edges. I had someone raise and lower the pedal so I could get to the entire path of the cable. If I ever get my replacement cable to work I will monitor how this plan worked.

[David Hodgkins]

I don't know if you want to hear this or not but I ditched the cable and went with Mike Forte's hydraulic system. Super smooth, easy to install during the build and no cable to wear out.

https://thefactoryfiveforum.com/attachment.php?attachmentid=40129&d=1427898926

Worth considering?

:)