77tony

Please put me down for 5. TIA. 77tony

oaros

Beige will do.
thanks

kurt_1

just to keep you updated: I have made some first tests with the beige candidate material. It turned out that the mechanical properties, i.e. tear resistance, are not suitable for the purpose.

I had not thought it that difficult since silicone is so ubiquitous but all really heavy duty stuff I came across is used in construction and cures a few mm per 24 hours. The silicone used for making copies of artwork and for hobbyists turned out to be mechanically limited.

The only silicone that is durable and cures fast is the dental impression material but that comes only in green and violet blue and costs a fortune.

I'll keep looking for alternatives.

Kurt
_____
90 S4 satin black metallic
928 OC Charter Member

canadagord

Hey Kurt (and everyone else...) what about these? Apologies if we've covered this type of solution in a previous message, too lazy to go back and read them all...

If you slice/cut the seal, then wrap it around the end of the cable, then heat shrink (and maybe add a mini-twist tie) , would that work?

Here's the link (it's from Australia, but they would have similar stuff elsewhere...)

http://www.ferret.com.au/c/stockcap/...tockcap-p16201

gordo

canadagord

Doh... first post... crap.. that's terribly lazy... sorry everyone...never mind... carry on...

kurt_1

LOL!

But your post did prompt me to search for silicone end caps and there some suppliers of silicone plugs used for masking in powder coating processes:

one example in the USA:
http://www.componentforce.com/category/19/silicone-caps
they also have cone shaped caps:
http://www.componentforce.com/catego...cone-cone-caps

...and another one in the UK:

http://www.afac.co.uk/product-catego...ng-pins-studs/
they have the same range of cylindrical and cone shaped caps

They come in different colors and seem to be available in small quantities.

They could be fitted like my versions: first splitting them for application and then securing them with a wire clip.

Maybe someone local could ask for a couple of free samples and check them out. This way you could probably have something much faster and cheaper than my handmade caps.

Kurt
_____
90 S4 satin black metallic
928 OC Charter Member

canadagord

Love the second link, they look like they would work... might have to drill a suitable hole at the end as well as splitting, but they might work... Anyone in the US want to get samples? Might be faster for someone US-based than me here in Canada...

Good find Kurt!

kurt_1

Did someone manage to get a sample of the silicone plugs?

In the meantime I found a material that seems suitable. It is called Elastosil 4670 from Wacker Chemicals. I got a material sample and it looks and feels alright. It is white-ish in color, like the higher-quality erasers and should reasonably resemble the color of the original caps.

I got a lead for a distributor who will sell my a single pack of the smallest unit (5.5kg) and see what it cost. Then we can decide how to proceed.

Kurt
_____
90 S4 satin black metallic
928 OC Charter Member

kurt_1

Not too good news:

the silicone I mentioned above is pretty expensive in this small quantities. They want around 300 EUR for the smallest package.

With preliminary interest for 75 caps, that would add 4 EUR to the cost of each cap on top of a bit more than 1 EUR for the wire clip and the mold material. So the cost for each cap would be 7 USD, valid only if no-one looses interest.

Shipping would be on top of it, even though shipping from Germany to the US could be handled cost effectively since some people have volunteered to help with bulk shipping and distribution.

Even with me working for free, this is still pricey enough for people to expect a good and durable product. However, I have no idea how long this material will withstand the harsh conditions in the engine bay.

So I have a feeling that this is not a viable way forward, especially since the silicone plugs mentioned above might be a way cheaper and probably more durable alternative which should be evaluated first.

What do you think?

Kurt
_____
90 S4 satin black metallic
928 OC Charter Member

canadagord

Thanks Kurt... probably too expensive for what they are (my opinion only...) I can ask for samples from the company we found, but am unsure as to what sizes I should ask for? Any idea? If you could have a quick look at the options, I'll reach out and get samples...

gordo

kurt_1

I agree, it simply isn't economical.

I measured the plastic end of the bowden cable and the OD is 5.5mm with the "barb" at the end measuring 6.3mm.

I guess if you want to use a cone, you would need to slip it 3-5mm over the end to leave some room for the clip. So I start with the 5.8 mm ID version.

You might need to remove a v-shaped piece of material from the larger end to enable the ring clip to compress the cone.

It would be nice if it turns out that simple!

Kurt
_____
90 S4 satin black metallic
928 OC Charter Member

canadagord

Just requested samples now... will let everyone now when they arrive and what they look like... Minimum order is qty 250, but once I see if they actually work, I can always call and see if they'll do something for us...

Stay tuned...

gordo

snoz

Talk about a thread hijack.

TheoJ

Maybe these cones would fit:
http://www.vital-parts.co.uk/silicon...caps-332-p.asp
I requested a sample.
regards
Theo

kurt_1

I realized that in Post#26. That's why I offered to start a new thread.

Kurt
_____
90 S4 satin black metallic
928 OC Charter Member