Brake cable wisdom please - 1.6mm or 2mm?

[JCS]

Looking for some advice on brake cable options. Specifically, should I stick with 1.6mm inners or change to 2mm inners?

I currently run 1.6mm inners with M900 XTR canti's and MT-63 Deore levers. This is generally OK, BUT the cable end is quite small for the brake lever and does not seat properly. Instead of seating vertically (as it should), it seats horizontally in the lever. I got a set of plastic c-clips (pic below) to try to correct this, but they are too thick to fit in the MT-63 lever so I can't use them:



BITD I used to run 2mm inners with 6mm outers and on the cable ends I used 'stepped' caps so the 6mm cable and end cap would fit in the frame braze-on (which is 6mm diameter). See old pic below. This worked fine and the cable end cap was bigger (I think) and seated properly in the MT-63 lever.


Questions for all you wise ones:

1. Do you know if 2mm inner brake cables have a cable end that seats properly in Deore MT-63 brake levers?

2. Do you know where I can buy the 'stepped' cable end caps (I have done a quick search, can't find any)

3. If I use 2mm inners, will they fit in the straddle cable directly below, or would I need to change to the straddle cable in the bottom pic?






This is a pretty random question but if anyone has any tips, I am grateful to hear.

 

[Tootyred]

I buy venhill large cable ends for motorcycle clutch cables....they slip over a standard cable end and make them the right size for older levers....

 

[Tootyred]

https://www.venhill.co.uk/cables-an...it/ferrule-for-lb2ts-conduit-8mm-od-f201.html

 

[Tootyred]

As for the other end...try the brass shims...rather than plastic ones...

 

[JCS]

Top advice, thankyou!

 

[JCS]

I found a good solution to this problem, so I am sharing it here in case it's useful for others.

I switched from using 1.6mm brake cable to 2mm brake cable because I prefer it, and the cable end fits properly in the brake lever.

These are the components I used. Mostly from Venhill UK , who have excellent service.

1. 2mm brake cable. Available from various sources. The cable end fits the brake lever housing and doesn't twist.



2. This is what I used for the cable stops:



3. This is what I used for the brake lever barrels (Deore XT M732):

 

[FluffyChicken]

For the purist info.

.6mm is the default XTR M900 cable as 2mm had pretty much been dropped by then, but 2mm was still an option at the start (1992)

I assume the original prosets straddle would need to be used, or did you find you can use the newer style?

 

[JCS]

The 2mm inner fits in the newer style Shimano straddle (the one with the tube), so I used that.

 

[Tootyred]

2mm is a standard for motorbike cables. You can buy solder up kits on ebay if needed.
Venhill stuff is good, but for general cables pricey.

 

[Rikoned]

Weinmann 2401-1 stainless 2mm cables have two different sized barrel ends:
9mm wide x 7mm dia.
10mm wide x 8mm dia

I'm happy with the ones I bought from here:
https://www.ebay.co.uk/itm/134222650067