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EBrake Help Needed - Cable Stop - Swege Ends - Custom?

ZombieK5

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I am involved in an unrelated project replacing the emergency brake cables on our old Ford Explorer. I am having to make a custom cable stop on one of the lines that leads from the emergency brakes to the intermediate cable. While doing this I realized I'm going to have to do the same thing on my K5 once I get a little further down the road. I am having to cut one of the E-brake lines that lead from the rear end forward. One of them is too long. I need to cut the wire and somehow put a new cable stop on the end. Is there a way to crimp a stop onto the cable and or do I have to melt a lead barrel on to it. I've seen Dorman sells universal cable stops that use a screw to secure the stop on the cable however I don't see how that can be effective for an extended period, especially on an e-brake.

When I purchased my Blazer it came with a series of AC Delco brake line sets in boxes. I laid them out not too long ago and realized that I will have to do some cable cutting to make it fit. The ends on those AC Delco lines look like the barrel and seen in the attached photo.

Is there a way to make those ends without using molten lead and a mold? Does somebody make a end stop that can be crimped?

I searched the Forum and found some threads related to this topic but did not find any related to making custom cable stops.

BC95408.jpg
 
Man there aren’t a lot of options. I had a similar issue on mine in that my 14bolt used the early style cables to the backing plates. But my truck being a ‘91 has the later style the didn’t have the same length cables from the axles like the earlier ones.

I had to find a custom length intermediate cable to try and match it all up. I thought I may have to cut an end off and re-do a cable stop. But what I ended up doing is pouring through the Dorman parts catalog online and looking for a cable that was the right length for my needs. I found three that were close and ordered off of Amazon and tried them out.
 
I saw those... What crimper did you use? Is it inexpensive enough? I'm figuring I'll need to make four or five of these stops so it may be worth the purchase.
I have one of those hydraulic cable crimpers off Amazon I think it was around a hundred bucks or so. But I’m sure you could crimp them some other way.
 
I have one of those hydraulic cable crimpers off Amazon I think it was around a hundred bucks or so. But I’m sure you could crimp them some other way.
Fantastic. Would you mind sending me a picture of it and a model number? I want to use it as a comparison between models.
 
Fantastic. Would you mind sending me a picture of it and a model number? I want to use it as a comparison between models.
TEMCo TH0006 Hydraulic Electrical Cable Lug/Terminal Crimper Kit with 18 Die Sets 12 AWG - 00 (2/0) (5 US TON) https://a.co/d/bIHYJN9
Looks like it’s gone up in price quite a bit since I bought mine.
 
I have one of those hydraulic cable crimpers off Amazon I think it was around a hundred bucks or so. But I’m sure you could crimp them some other way.
AMAZING. I got a $55 version of that crimper. Figure I'd be doing less than 20 total crimps once I do the K5's eBrake. The cable for our Explorer came out great. Easy peasy too! Leaves the cable end in a hexagon shape but it works great.

20230619_141310.jpg

20230619_141321.jpg
 
AMAZING. I got a $55 version of that crimper. Figure I'd be doing less than 20 total crimps once I do the K5's eBrake. The cable for our Explorer came out great. Easy peasy too! Leaves the cable end in a hexagon shape but it works great.

View attachment 450047

View attachment 450048
Awesome man. I know I was happy when I did mine. Glad it worked well for you too.
Nothing better than adding tools to the box!
 

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