What tools do I absolutely need to replace brake cables?

Question

I'm happy with the job I did replacing the drivetrain on my road bike, and I'm ready to tackle replacing the brake cables. Unfortunately, I did a little research and it's been suggested that I need a few new tools. If I go by what's been recommended, I'll be spending well over $100 on tools.

I'm okay with buying used tools or brands other than Park Tool, but I don't want to cheap out on the brakes. Stopping is pretty important!

• Fourth hand cable stretcher - I think this is one tool I'll need to get, or something similar. I see Pedro's makes a version of it, I'm not sure if it's made as solidly or not. What should I look for when buying one of these?

• Cutter pliers I have a couple of similar cutting pliers, I don't think I need to get another one. Or is there something special about these?

• Cable housing cutter - Looks to me like this is a fancy wire stripper. Is there anything about brake housing cables that I need to know that would make using a sharp wire stripper problematic?

Please keep in mind that I'm not a shop, and will be replacing cables maybe every year or two at most. I'm okay with the job being less convenient, but not less safe.

Answer 1

Fourth hand cable stretcher - I think this is one tool I'll need to get, or something similar. I see Pedro's makes a version of it, I'm not sure if it's made as solidly or not. What should I look for when buying one of these?

Never found I needed one, typically I pull the inner brake cable as far as possible then close the brake calipers all the way (i.e., engage to the rim/disc), then attach the cable. Usually, I missed a bit of slack pulling by hand, which is taken up by the caliper return spring. You may need to repeat a couple times to get everything settled.

Cutter pliers I have a couple of similar cutting pliers, I don't think I need to get another one. Or is there something special about these?

If you have cutting pliers that could cleanly cut shifter inner cabling, then you are probably fine.

Cable housing cutter - Looks to me like this is a fancy wire stripper. Is there anything about brake housing cables that I need to know that would make using a sharp wire stripper problematic?

This is the only item on your list I found invaluable, bit it depends on the quality of brake cable housing you intend to. If you already have cutters that can cleanly cut shifter cable housing then this will likely work on regular brake cable housing that uses a coiled construction. If you are using "compressionless" brake housing, then only the best of the best cutters can make a clean cut.

Cable housing cutters are a special type of cutter that does a shear cut, I found most general cutters will leave large burs at the end of the cable housing (which you can file away or trim with a blunt cutter) or will not make a clean cut through higher end housing. .

Answer 2

There is nothing special about Park Tool's side cutter pliers. I would guess that they re-brand reasonable quality generic ones rather than make their own. Any decent quality, sufficiently heavy duty ones will be fine.

Cable cutters are handy to cleanly cut brake and gear shift cable, but not strictly necessary. Any cable stout cutter than has the same sharp, curved cutter profile will work approximately as well. I personally use a Dremel tool with a thin grinding cut-off wheel, but I owned that before starting to do bike mechanics.

Cable stretcher definitely not needed. Those are for pro mechanics putting bikes together or doing repairs all day long who need to save time. Asking a friend to help is just as effective.

Answer 3

Well the first question is if they need replacing. You would be astounded that even an old rusted cable works fine after it has been oiled, freed and cleaned.New or old, they all need regular oiling to stay free.

Eventually the core strands break, usually at the cast lump, which is fatal. The core can also break a strand inside the sheath, which also means replacing the core. Replacing the core is easy.

Cracked/worn plastic on the sheath should be repaired since it is letting water in. Wrapping with stretched insulation tape works.

But no, you don't need special tools to replace or adjust.

Inner cable can be cut with heavy sidecutters, pliers, or cold chisel or grinding wheel on a drill/dremel. You cut it off AFTER it is installed and adjusted, and you wrap the strands or heatshrink before cutting.

Old square nose pliers have a shearing notch/grove in the hinge joint, separate from the wire cutter in the jaws, which is for exactly this.

Outer can be cut on a grindstone/drill/dremel, but you can also take the old ones to your bikeshop with you, and they will cut some exactly the same length.

Cables are hardened steel. Only use big, blunt cutters - never fine sidecutters or tools.

Answer 4

For cutting wires and bowdens I use cold chisel and anvil as a counterpart. And a knife to cut the protecting layer to find the place to cut.

Answer 5

Cable housing cutter - Looks to me like this is a fancy wire stripper. Is there anything about brake housing cables that I need to know that would make using a sharp wire stripper problematic?

As a few other respondents have already said; if you only get one of the three tools you've listed get one of these or an equivalent from another brand.

The curved edge of the cutting blade serves to not squash & mangle the cable braiding as it does the housing case. You have to remember there's metal in the housing also; which is wound in brake housing & sort of braided in gear housing.

The idea of effective cutting is not to mash the housing metal into obstructing or causing friction to the threaded inner cable.

So they're not really strippers as you say. Think of the curved cutting jaw like a parrots' beak vs. your own front teeth in terms of a different cutting action.

In my years of amateur twiddling experience before I bought dedicated cutters I for a while merely used the generic side cutting pliers as you suggested. I found they tended to mash and deform the cable a little; making them a bit more prone to catching and fraying during set up. I only use them these days for quickly dismantling old junk bikes with seized or frayed beyond re-use old or cheap cables.

re The Dremel option. Unless you're wanting to invest in a Dremel or equivalent powered tool for other purposes; I think they're a little overkill just for cables. I do own and use one; but it tends to be stored away for more infrequent use on other jobs. It's a pain to pull out, set up and pfaff around just for what is otherwise a quick snip. They're also a little harder to keep a square cut than simple hand tools and being they generate heat as they cut, you want to keep your awl (I use a sharpened spoke) handy to clear the housing opening straight away while the housing liner is still soft.

As ever with any tool there's a little subtlety to each ones technique. Practice clean & square cutting on old housing scraps; or worst case cut the new stuff deliberately too long by a few inches and "chomp" it back gradually on the waste side of the your final marked (and perfect!) cut.

Answer 6

All these tools are professional and you shouldn't have them, but you don't need anything but better pliers to replace them once or twice a year. You buy a cable to measure, etc.