Control Wire 2 Plunger Assembly

[Ohio-Rider]

I've never assembled one of these before so I need a second opinion. Is this the right order of things? If so, can someone tell me how do I permanently attach the wire-end with the slot in it to the wire? Is it a simple crimp job?

[mbskeam]

what is this brand?

mine does not look like this....

http://www.geocities.com/mbskeam/pics3.html

is the slot thingy loose off the cable?
you could solder it on to the wire....
got a pic of the plunger, where the ferrule screws into?

[FlatHeadSix]

I think on that style all you have to do is push the wire through the way you have it shown and put a short right angle bend in it so that it fits into that slot and then clip or file it off flush with the outside. When you screw the retainer into the plunger it will lock it in there.

mike

[LittleAl]

mine looks like mbskeam's does in his pics

[Ohio-Rider]

It is the control kit sold by Flat Land Motorcycle. The strangest part about it is that even if I where to bend the wire 90 degrees and solder it all together, the hole in the plunger where this all screws into is a good 1/8” deeper than the screw and anchor put together so my control wire will have 1/8” slop in and out after everything is tightened up. I guess I could always put ¼” long slug down in the hole in the plunger before screwing in the control wire then everything would tighten up. I’m guess I’m going to need to think this over a bit more.

[indianut]

/This is definitely one of those areas where you DO NOT WANT REPOP!! Send that stuff back and buy crusty old HD parts and restore them and it will work well forever.

[VintageTwin]

Colony makes the '49-53 plunger (2304-2) and the '54-74 (9514-2) and the roller and pin kits for both.

[FlatHeadSix]

Ohio-Rider,
I've got a set of those in one of my bikes and I don't remember having any problems installing them. I didn't crimp or solder anything, I bent the control wire at a right angle and clipped it off flush with the outside diameter of the slotted slug. When I screwed the retainer in it all tightened up, no slack. Maybe they drilled your plunger too deep?, or the set screws are too short? Are both plungers drilled to the same depth?

Where's Kurt?, he sold the things so he should know how to make them work for you. Give him a call and let us know what he says.

mike

[neilw]

What year and model did you tell the seller you were working on??

[Ohio-Rider]

I'll call Kurt tomorrow and see what he says about these things. It must be that a few of these plungers while being manufactured got drilled to deep and and I got two of them.

[mbskeam]

or you could put a small lead fishing weight into the plunger then screw in the wire/fitting,
it should lock it up tight.......

[Ohio-Rider]

That's probably what I'll end up doing Mike. Sure wish I'd gotten the plungers with the set screw like yours. Thanks for the help everyone. -Steve

UpDate:
Talked with Kurt today and he's going to fix me up with what I need. Only six weeks left till riding season is here in Ohio so I need to speed this project up a bit.

[Ohio-Rider]

Ok ¦ One last obstacle and this project will be complete. I've attached the cable to the plunger and run the cable down to the S&S carb. Now I need to put a cable barrel onto the loose end of cable at the carb. I've been searching high and low but haven't been able to find where I can purchase these cable barrel ends. Anybody have a source for theses?

[Panacea]

Have you tryed the HD parts counter?

[mbskeam]

got mine at a shop, these are around ......
I think some of the late model bikes used these