Sharp bends in Cable Route

[scottaharper]

I just switched the bars on my wife's bike from Zipp SL70 Ergo alloy bars to Zipp SL70 Aero carbon bars. She really likes the feel of the bars, but I am having trouble getting the brakes to run smooth. Previously, with the same levers and calipers, the brakes were great. But since I installed the carbon bars there is significantly more resistance at the levers. My hypothesis is that it is because of the sharp bend that the cable is taking right near the levers. The bend here is much sharper because the carbon bars are heavily flattened, so the route of the cable to get from the top of the bar where the lever is mounted to the bottom where the cable routes is much shorter. Both bars use full housing runs, so there are no addition cable ends etc to cause problems (in fact I am running the same cables and housing). And this is happening even on the front brake with its short cable run and no breaks in the housing. So, I am calling on the collective wisdom of the forum to help me with two questions:

1) Does my hypothesis sound reasonable?
2) If so, Is there a magic bullet (particular brand of cables or housings, etc) that will help me fix the problem?

Thanks,
Scott

[kramnnim]

Maybe segmented housing? (ilinks, etc)

[bobswire]

I had to extend housing on a couple of bikes and used jagwire double ended ferrules to achieve a smoother transition.

http://www.ebay.com/itm/140887668695?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Looks like this when set up.
http://i61.tinypic.com/2vjocau.jpg

http://i62.tinypic.com/34ovodx.jpg

[carpediemracing]

Due to the "all the way to the right" packing method of getting my bike in the car I blew out 2 sets of shifter housings in a couple months each.

I went to Nokons and it's been fine since.

More to your question, since the Nokon switch I also route my housing much more aggressively. For example I used to cross the shifter cables in front of the head tube and then re-cross them on the downtube. Now I don't bother.

Friction is down - I thought the cable head unseated or I didn't take the slack out of the cable because I didn't feel resistance - and I can run much more aggressive routes.

I can't give any observations on other segmented housing. I thought about trying a different segmented housing but now that the corrosion issues seem to be resolved I didn't see a reason to try something else. I use my older Nokons under the tape and inside the (full housing necessary) top tube. The nicer/newer looking pieces I use where it's visible.

[Ralph]

I had to extend housing on a couple of bikes and used jagwire double ended ferrules to achieve a smoother transition.

http://www.ebay.com/itm/140887668695?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Looks like this when set up.
http://i61.tinypic.com/2vjocau.jpg

http://i62.tinypic.com/34ovodx.jpg

Nice! No waste.

[Lewis Moon]

I had to extend housing on a couple of bikes and used jagwire double ended ferrules to achieve a smoother transition.

http://www.ebay.com/itm/140887668695?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Looks like this when set up.
http://i61.tinypic.com/2vjocau.jpg

http://i62.tinypic.com/34ovodx.jpg

I've used the Jagwire in line cable adjusters to do this too. Looks cool and it's functional too!

[ultraman6970]

Scott, which levers are we talking about here?? If cable is too bent what you say is correct but is hard to say w/o knowing which lever we are talking about you know.

Second, how are you routing the cables?? one at the front, one at the back?? both at the back? both at the front??

Campagnolo for example, you have to put one in the front and one in the back, because if you go front front or back back, or is the shifting or the braking that is affected big time.

With shimano no idea because I dont use that stuff since a very long time.

[scottaharper]

Campagnolo Super Record 11 levers with white logos (no red 11), Campagnolo cables and housing, 1 front/1 back routing since the bars have a single cable sized groove on the front and back.

[ultraman6970]

Ok... this is what I would do ok?

Get jagwire housing just because is cheaper than the campy one, and cut a new piece for the FD and RD... put a ton of grease in the cable before passing the new casing, new casing will bend different (harder to bend) than used casing and that might help to your cause.

Hope this helps.

[oldpotatoe]

Campagnolo Super Record 11 levers with white logos (no red 11), Campagnolo cables and housing, 1 front/1 back routing since the bars have a single cable sized groove on the front and back.

Could be that the housing is now too short or perhaps the housing isn't firmly seated in the ERGO lever hole..install housing and inner wire, attach to brake, then SQUEEZE lever hard, to seat and make sure it's not hung up on the pil of the lever. NO FERRULES in the lever for brakes for 2009+ ERGO, any of them.

[Lewis Moon]

Could be that the housing is now too short or perhaps the housing isn't firmly seated in the ERGO lever hole..install housing and inner wire, attach to brake, then SQUEEZE lever hard, to seat and make sure it's not hung up on the pil of the lever. NO FERRULES in the lever for brakes for 2009+ ERGO, any of them.

Derailleur cables too? Because I cant seem to get them in I don't use them.

[oldpotatoe]

Derailleur cables too? Because I cant seem to get them in I don't use them.

NO FERRULES in the levers for 2009+, latest shape, ERGO...der housing has to be 4mm for 2009+ levers, cut clean, into holes..same for brake housing, 5mm. IME, best to route der housing behind handlebars instead of front.

2008-1998 ERGO-YES ferrules for ders, NO for brake. Older levers, depends on year but YES for ders, sometimes for brake, 1997-1991.

[Lewis Moon]

NO FERRULES in the levers for 2009+, latest shape, ERGO...der housing has to be 4mm for 2009+ levers, cut clean, into holes..same for brake housing, 5mm. IME, best to route der housing behind handlebars instead of front.

2008-1998 ERGO-YES ferrules for ders, NO for brake. Older levers, depends on year but YES for ders, sometimes for brake, 1997-1991.

This is why I have a Campy crush on Peter. The guy knows his schmidt.