How to bend a heater control cable - Toyota

[WoodsTruck]

Working on a Toyota pickup and the control cable (actually a single strand hard wire) that runs the heat valve is broken. The spare truck we have for parts looks to be broken in exactly the same place (detecting a pattern here). Since I have a spare heat control unit, I'm looking at robbing the wire out of one of the longer spare control units but need to put the "Z" bend in it to fit back into the control arm.

Any suggestions on how to bend a tight "Z" so that it will drop into the 1/16" metal control arm?

Picture is of a similar setup so you get the idea of the wire in the control lever hole.

Thanks

 

[38 Dodge Coupe]

I would use needle nose pliers to put the "z" back into it.

 

[nutjob]

I doubt needle nose will work, that cable is very hard. Tried that years ago for the mini bikes and mower repair. But your local small engine lawn mower service is the answer. They have special pliers that will make that bend since lots of mowers use that type of cable.

If you like buying new tools, search for Z bend pliers.

Also lots of old cars/trucks used coiled end wire. I have the K-D 495 Coiling Pliers for this.

Kevin

 

[WoodsTruck]

Thanks for the responses.

The business end of the wire has a coil wrap for the heater valve control.

I'll check the plier option.

 

[kelpaso1]

http://www.flyrc.com/make-your-own-z-bend-pliers/

 

[WoodsTruck]

Kelpaso - thanks for the link. I found that when searching for Z bend pliers.

I tried bending a 90° into the wire yesterday to see if it was possible. Super tough stuff so I'm liking the dedicated pliers that form the bend accurately. Pliers appear to go for <$20 so likely cheaper than a visit to the small engine service guy, with the added benefit of another tool in the drawer and who doesn't like that?

 

[nadogail]

Thanks for posting.

 

[LXCam]

If you got a map gas torch get it red hot do your thing and let it cool naturally.

 

[Jazz1]

fishing tackle making pliers,,i don't know the technical name for the "pliers" but they got a notch in them to hold stainless wire for bending, although the Z bending pliers KELPASO1 suggests would be the cats ***

that looks '80's or early '90's controls?

 

[The Cobbler]

I was going to suggest what kelpasso linked, but only in words. he's got the answer

 

[Rlfd213]

Vice or vice grips and a pipe. Use the pipe for the contour

 

[toplessHO]

I have a tool thats made just for that ,very thick with a small slot cut out. Works perfectly for bending such cable
Im sure with an angle grinder you could make such a tool from 3/8 keyway stock or something similar

 

[Kevin54]

Heat it, bend it, and oil quench it.

 

[toplessHO]

heres the tool
https://www.amazon.com/dp/B0018U2964/?tag=atomicindus08-20