944 handbrake cables
 

OK. I have the beetle cables and the 944 ends. What type of clamp would be suitable for this situation? Does the kerscher kit use beetle cables and 944 ends? This is the last piece left in my conversion.

Thank You

Hi,
I just used the beetle handbrake cable as is when I did a 1983 944 swap on my former 1303. The only thing you have to change on the 944 handbrake internals is to make yourself a new plate to which the handbrake cable is connected. The 944 part is 4 mm thick, so I sawed a 4 mm thick iron plate to match the 944 part, only made some sort of 'hook' on it, in the place where normally the 944 cable is attached, so the beetle handbrake cable can now attach itself in the 'original' way. Make sure the arch of the hook is a bit wider than the 944 part in that way, so the hook is strong enough.
Its difficult to describe this part in 3D...
I hope you can now make your own as well.
Walter

There is a nice picture of the part on the 3rd page of the brake gallery on the main site.

Sandeep

The Kerscher kit consists of 944 ends that crimp onto the Beetle's cables. These are used in conjuction with the Kerscher spacer for the cable sleeve into the backing plate.

Kerscher sells only the ends? Any idea how much? Where can read German here? Thanks.

Sprint.

Remember in that other thread where I posted how to navigate to the ball joints on the Kerscher page, well the rear cable parts (including the ends) are on that same page.

They are 15 EURO each but you'll need the spacer also @ 18 EURO each.

Spacer? What's the spacer for?

It's used to offset the difference in length between the 944 and Beetle cable.

Oh... Thanks.

Hmm... 15 Euros x 2 + 18 Euros x 2 + Beetle cable.

That's 66 Euros excluding the Beetle cable. I think I can get the local handbrake shop to make some for 60 Euros all in, ready to install. Anyone interested? He can get the connectors made but dang.... We are going to need a BIG order.

I'll talk to him if there's any interest.

What I meant by 944 ends was that I have approximately 10cm of the 944 cable with the ends attached to it. So I was wondering what kind of cable clamp or other method of attaching the 944 cable + end would be the best.

Thank you for the replies.

Ok,

Here's a trick. Go to a good handbrake cable shop. They will be able to unclamp the connectors and then re-clamp them on your Beetle cables.

But make your measures right! They can only do it once more as the connectors won't be as strong after repeated unclamping and re-clamping....

Good luck! And do take down some number and share with us here.

By the way, how did you locate just the end connectors? Everyone seems to want to sell me a whole cable!!! Grr..

Got any more lying around? :D

Sprint.

The cable ends are available new from Kerscher for 30EUROs.

As for the splice for the cables that vw1303 wants to do, just go to a hardware store and ask for a crimp on cable splice or as SprintStar said you could just use the ends.

I cut the cable ends off when I was dismantling my 83 944. That is why my question was kind of a special case because you usually don't have the 944 cables to begin with.

Will they be strong enough? I'm not sure if they can stand up to the weight of the car on a hill.....

Sprint.

That I can not answer as I personally have not, and would not, use this method. I merely posted a known way to splice cables, a fence repair kit comes to mind as well.

Anyone has tried this?

Sprint.

I wouldn't mess with the ends of the cables. Unless you now the correct crimp pressure and radius. I simply tried what I read on here last year, 'shouldered M4 buttonhead screw and nylock nut aside a new stock '03 cable/1mm washer/stock 944 brake shoe spreader. Slack enough so the cable dosen't have to bend.

The guide tube on the caliper mount needed shortening by ~15mm and 3 layers of heat shrink tubing make a nice strong, straight, sealed outer-cable splice. Cable outer's are 10mm zip tied to the arms. Simple, cheap and very reliable.

The 2 M4 screws I used could together, carry the weight of the car.

The effect of the ~6mm misalignment is negligible. After 14 months daily use, all is sweet. I may yet modify the spreader like in the gallery, tho' it doesn't give me any real concern's.

Matt

Good job!!!!:D

Sprint.

My "moto" is avoid the hassle and the guesswork where you can.
Buy beetle to 944 e-brake cable adapters and that's it.

www.kerscher.de (official site in German)
www.germancarcompany.com (official reseller in UK)