I am swapping a Tacoma Axle under my 88 4Runner and it requires some E Brake work. The way I plan on shortening the E Brake cable requires me to cut off an existing steel crimped cable stop at the end of one side of the E Brake cable on the axle housing, then crimp on a new one to the now shortened cable.

Looking for advice on the most correct method for installing a new cable stop on the end of this 5/32nd cable. I might be overthinking this but would aluminum or copper cable stops be strong enough in this application? I can't seem to find steel cable stops or much information on how to crimp/swage them, everything is about aluminum or copper ones. Its bothering me that the factory cable uses steel and I might be replacing it with a less secure method.

Here is a picture of what im trying to cut off and replace on the shortened cable.




Any advice from someone who knows more about this would be really appreciated, thanks!

 

I researched this awhile back to make cables. Look into custom cables. Motorcycle guys make them for old bikes.

I think copper or aluminum would be too soft.

 

I had to do this when I did my tacoma axle swap. I used a crimping tool and ferrules I found at home depot by the rope a metal cables. I believe used t100 cables and kept end by the belcrank the same but then cut them to length up by the splitter. This was 10 years ago so I could be off a bit too.

Recently I was making a over the bed rack that I needed cables to unlatch the catches and watched videos on YouTube and saw people making them from solder but I'm not sure I would trust that on the brakes

 

Thanks for the input, I think so too.

I assume the ferrules you got at home depot were aluminum? thats all I have been able to find there. How has the cable held up so far? Thanks for the reply

 

Yeah, I'm pretty sure they are aluminum but I've never had any issues with them. Maybe mcmaster carr or fastenal might have some steel ones. Shipping is going to suck though.