Casting a cable boss with your own hands

This problem often occurs - the boss at the end of the cable, fixing it to the gas handle, has come off. Usually the problem is solved by replacing the cable assembly, but you can try to restore the clamp, which I gladly did.

Required tools and materials

• Gas-burner;
  
• Angle grinder with cutting disc;
  
• Drill (drilling machine) and a set of drills for metal;
  
• Pliers;
  
• File, knife;
  
• Calipers;
  
• Tin;
  
• Dielectric tape;
  
• A bolt 3-5 cm long and a piece of metal rod with a diameter of 6 mm (the length should be 2-3 cm longer);

Preparatory work

First of all, we measure the diameter of the hole (where the cable boss is inserted) on the gas handle using a caliper. It is 6 mm, so we need to take a metal drill of the same size. We clamp the bolt in a vice, setting it vertically, and drill a through hole in the center.

Next, you need to make a side slot parallel to the length of the bolt up to 10 mm. We do this using a grinder, holding the bolt at an angle for convenience.

Next, install the pin in a vice and put on the prepared bolt with the cut facing up.The resulting recess should correspond to the thickness of the seat on the gas handle.


Next, we trim the torn end of the cable evenly. To do this, wrap it with electrical tape (one layer is enough) and make a neat cut with an angle grinder.


The smooth edge needs to be fluffed up a little. To do this, we clamp it in pliers and bend the cable fibers to the sides with any metal tool. The end of the cable prepared in this way should be no more than 2-3 mm and fit into the bolt hole.

Boss casting

Through the slot we insert the fluffed edge of the cable into an improvised casting mold.


Using a gas torch, melt the tin so that it fills the void inside the bolt.


Next, we heat the upper part of the bolt and use a piece of steel wire to check for voids.

In case of excess melt on top, simply brush it off with a metal object before the tin hardens, after which we allow the entire structure to cool.


Next, you should reinstall the pin in the vice, pulling it up 1 cm. Gently tapping the head of the bolt, we push it deeper onto the metal rod, which thus pushes out our casting.


We remove the excess tin (where the slot was) with a knife and lightly process the edges of the boss with a file.

After this, you can install the cable on the gas handle by inserting the restored clamp into the seat. Please note that there is no play in the boss - this will have a positive effect on the service life of the restored connection.

Safety precautions

Carrying out the above actions requires compliance with a number of safety rules that are provided for working with power tools.When using an open flame of a burner, first make sure that there are no flammable or explosive objects nearby. Also, never neglect personal respiratory protection (respirator or mask) to protect yourself from molten metal fumes.
After the work done, you will have the casting mold, and you can always help your friends if they have the same breakdown. In this case, recovery will take much less time.

Watch the video of the process