How to quickly cast a cable boss without an injection mold

How to quickly cast a cable boss without an injection mold

Sometimes such a nuisance happens as the cable breaks and the factory boss at the end flies off. To make a new one, you need an injection mold that will form the outer contours of the metal. Of course, you can do it yourself, but it will take a lot of time and effort. And it’s not a fact that you will have all the parts for it and the manufacturing machines.
I will demonstrate a simple way, a life hack, on how to cast a new boss in literally 5 minutes. And we’ll make a mold for filling from a piece of wood. Yes, yes, it’s made of wood. Almost everyone, even the most shabby craftsman, has an ordinary board and drills.

Will need


  • Flux, preferably in paste.
  • Tubular solder.
  • Gas burner with cylinder.
  • Wooden block (piece of board).

We cast the cable boss into a wooden block


It is necessary to securely secure the block, say in a vice. Next, drill a blind hole with a diameter of approximately 8 mm - this will be the future diameter of the boss.
How to quickly cast a cable boss without an injection mold

Then a hole is drilled on the side along the thickness of the cable, which passes through the large one.
How to quickly cast a cable boss without an injection mold

Let's start casting


Insert the cable into the hole from the side until it stops.
How to quickly cast a cable boss without an injection mold

Add plenty of flux.It will not only perform the function of adhesion of solder to metal, but will also protect the walls of the casting mold from destruction.
How to quickly cast a cable boss without an injection mold

Turn on the burner and heat up the flux. The wood begins to char immediately - this is normal.
How to quickly cast a cable boss without an injection mold

After 5 seconds, introduce tubular solder.
How to quickly cast a cable boss without an injection mold

Add it until it comes in and there is no excess on top.
How to quickly cast a cable boss without an injection mold

After the recess is filled, we continue to heat it so that the metal spreads evenly and no voids form inside.
How to quickly cast a cable boss without an injection mold

We are waiting for it to cool down. You can water it with water.
How to quickly cast a cable boss without an injection mold

Using a knife, we cut through the charred wood to free the cable.
How to quickly cast a cable boss without an injection mold

Here is the boss after casting. Rough, but the process is not over yet.
How to quickly cast a cable boss without an injection mold

We modify it with a file according to the dimensions of the factory boss. The metal is soft, everything is done very quickly.
How to quickly cast a cable boss without an injection mold

After processing it is indistinguishable from the factory one.
How to quickly cast a cable boss without an injection mold

We install it in the brake lever and start using it.
How to quickly cast a cable boss without an injection mold

Watch the video


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Comments (2)
  1. Guest Yuri
    #1 Guest Yuri Guests 14 August 2019 22:22
    2
    Soft metal? Yes, take a nut, put it on the cable and solder it.
    1. Guest Evgeniy
      #2 Guest Evgeniy Guests October 2, 2019 10:03
      1
      as in the joke, modify it with a file