Roll your own - Automotive replacement control cables

Joined
Apr 13, 2025
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637
I like older cars. But as time marches on it's getting harder to find replacement sleeved, braided control cables.

I think you'd need some kind of hydraulic press (I have a 20 Ton press), the right molds to place the end material in to press onto the cable, and the right size and type braided wire and sleeve, which would also need ends added.

I'm thinking you often could reuse any specialty formed mounts or plastic fittings once you have the old cable dissassebled.
Anyone doing this?

Right now I need a new brake release cable for my 1999 Dodge Grand Caravan and couldn't find one online.
The braided steel cable itself is .049in or 1.27mm which is close to 3/64"
Overall length is approximately 12 inches end to end.
I could actually re use the sleeve. It's just the cable that's frayed.

IMG_20260614_113525882.webp

I spent the last hour Googling the part I need and kits but didn't really find a good solution.
 
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I haven't delved into my normal search to find solutions, but there seems to be a lot of alternatives with a Google search of "Push-Pull Control Cables". Add "DIY" in front of the search if you want to make them yourself:
https://midwestcontrol.com/shop/index.php?route=product/category&tierOne=Cable Assemblers Subcomponents
https://www.lexcocable.com/products/push-pull-controls/
https://www.tylermadison.com/our-products/

Again, I did not study this much and am not trying to armchair quarterback. Good luck!
 
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