Is it possiblt to extend the control cables..?

TKAnderson

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Feb 3, 2020
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After a 6 month total restoration on my 84 Montauk, I just found out the control (throttle & shift) cables are about 2 feet too short due to the new console and position. I knew this might be a problem going in but put it on the back burner thinking there is likely an extension kit or alternative way to fabricate them. I'm running out of options fast, anyone have any ideas? They are older Mercury cables, I've attached a photo. Any help is much appreciated
 

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GA_Boater

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Only way to extend the cables by replacement with longer cables.
 

Bondo

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Ayuh,...... Welcome Aboard,..... As GA says, you need new longer cables,..... No extensions possible,......
 

GA_Boater

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How long will the extended cables be from the control to the motor connections?

You said you needed 2 ft. The box is 12 in. Where did you find a 1 or 2 ft.cable?
 

Scott Danforth

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the shortest cable you can buy is about 8 feet.

the difference between an 8 foot cable and the cable you need in the first place is about $5 per cable

so, since you really cant simply extend the cables 2 feet with your hypercomplexification device..... why not simply buy the cable you need
 

GA_Boater

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Gee, is the steering cable long enough?

Chris - Don't complicate things. All it takes is 2 bell cranks, pivot bolts, some bushings, a connecting rod, another unobtainable 2 ft. steering cable, cable ends and a place to mount the hardware. :facepalm:
 

racerone

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I think he might be promoting his " Fix it / work around / overthink it engineering shop " -----Longer cables would be too easy a solution. ----Just my opinion.
 

Scott Danforth

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I think he might be promoting his " Fix it / work around / overthink it engineering shop " -----Longer cables would be too easy a solution. ----Just my opinion.

I think that he cant see the forest because the bark of the tree in front of him.

can you couple two cables together, yes, been done for decades on e-brake cables

should you couple two cables together in a primary control situation, no. from a liability standpoint

is he overlooking that they dont make short cables and will need to end up getting the correct cables in the first place, yes.
 

TKAnderson

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Feb 3, 2020
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First and foremost, I have several sets of cables and new one's that would be a perfect fit, unfortunately I/we didn't account for changing the position on the controls from a lower seating side to the console we built. It didn't seem necessary at the time because there was some extra run-out at the stern, but the added height and loop necessary took it all up and left me short. The reason I didn't simply pull the control box apart and put in the correct length cables is 2 fold and the primary being that we rewired it with a new harness and if anyone here has done that, they would probably just assume give up the sport before doing it again. Secondly, the control box is positioned between the under and top side being secured below and the best way to get it out would be to pull the console, no thanks. Yes I know it's not the best design for serviceability, but it should last easily another 40 years and the next guy can enjoy himself. With the machines I have we can cut the cables anywhere, machine a "stop thru" to secure to the console, engine or this new extender and in the case of the extender machine and reverse thread a thru-bolt which acts like a toggle. The reason it is 12 inches is because you need an equal amount of play as does your control box from full forward to full reverse which in my case was about 11 and a half inches which means each side (FWD/RVS) will need 6 inches of run. While the engineering took a bit of noodle knocking due to the construction and function of the cables themselves, the box should jump out in about 10 minutes lid and all. And no, I am not marketing this, it's a well engineered piece of equipment for a well engineered screw-up. Having a shop has allowed me to 1-up many parts and components that are no longer available (I like to work on older rigs) or to satisfy an engineering/design element beyond OEM. In any event, I'm confident that through the years there's been a need for a unit like this and it could have likely served a purpose. With the new Remotes now, it's not even a thought. Thanks for all the help including the banter, that's always fun too.. :) I tried to post the picture but it told me the file was too big. I'll get on that and perhaps send some of the build as well...:)
 
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