Home > Products > Custom Control Cables

Custom Control Cables

Engineered for precision, durability, and smooth operation. We manufacture bespoke push-pull, pull-only, and mechanical cable assemblies tailored strictly to your application.

Anatomy & Design

The Structure of a Control Cable

A reliable control cable is more than just wire. It is a highly engineered system designed to transmit mechanical force efficiently while protecting internal components from harsh environments.

Inner Core Wire

The heart of the cable. Made from high-tensile galvanized or stainless steel, transferring the actual mechanical force.

Low-Friction Liner

A PTFE (Teflon) or HDPE inner tube that prevents metal-to-metal contact, ensuring smooth operation and reducing wear.

Outer Conduit / Casing

The structural backbone that resists compression and protects the inner wire from crushing forces.

Protective Jacketing

An extruded layer of PVC, Nylon, or Polyurethane that shields the assembly from moisture, UV rays, and chemicals.

Control Cable Structure
CUSTOM MADE
Customization

Choosing the Right Conduit

The outer casing determines how the cable behaves under load and routing constraints. We manufacture three primary conduit profiles.

Bowden (Spiral Wound)

Constructed from a single, high-tensile steel wire coiled like a tightly compressed spring.

  • Highly flexible for tight routing
  • Best for pull-only applications
  • Cost-effective standard choice
HEAVY DUTY

Long Lay (Stranded)

Longitudinal wires laid parallel and bound tightly, preventing the conduit from compressing under load.

  • Zero-compression design
  • Essential for Push-Pull systems
  • Handles extreme heavy loads

Braided / Armored

A woven steel wire mesh over the inner liner, offering maximum protection against crushing and kinking.

  • Highest crush resistance
  • Withstands extreme impacts
  • Excellent for harsh environments

Core Operation: Push-Pull vs. Pull-Pull

The internal wire determines how mechanical force is transmitted. We specialize in both major types of mechanical actuation.

Push-Pull Cables

Push-Pull cables feature a rigid inner core (often solid wire or armor-wrapped wire) housed inside a long-lay conduit. This prevents the cable from buckling when being pushed, allowing for precise force transmission in both directions.

Common Uses

  • Throttle control mechanisms
  • Hydraulic valve actuation
  • Gear shifting (Marine & Automotive)

Pull-Only (Tension) Cables

Pull-only cables rely on a highly flexible, multi-strand wire rope core (e.g., 7x19 construction). Because a flexible rope cannot be "pushed" without buckling, force is transmitted strictly through tension (pulling).

Common Uses

  • Parking brakes & clutch cables
  • Lanyards and safety tethers
  • Hood and latch releases
Terminations

Custom End Fittings & Machined Parts

A control cable is only as reliable as its connection point. We manufacture and swage standard fittings, or precision-machine bespoke ends based strictly on your CAD drawings and physical samples.

Clevis & Eye Ends

Standard industrial linkages manufactured for secure pinning, providing rotational freedom while handling heavy load transfers.

Threaded Terminals

Swaged threaded rods allowing for precise tension micro-adjustments in both metric and imperial thread pitches.

Ball & Shank

Commonly used in automotive and throttle controls, providing smooth, quick-release rotary connections.

SPECIALTY

Bespoke CNC Parts

Have a unique linkage? We reverse engineer and CNC machine custom end fittings in brass, steel, or aluminum to fit your exact application.

Industries

Where Our Cables Perform

We supply premium custom assemblies to manufacturers across a diverse range of heavy-duty and precision industries.

Agriculture

Tractors, combines, and heavy implements.

Recreational

Golf carts, ATVs, and go-karts.

Industrial

Hydraulic lifts, winches, and automation.

Automotive

OEM replacements, braking, and clutches.

Have a Unique Requirement?

Our engineering team is ready to review your CAD files or technical drawings. Let's build something exceptional together.

Chat with us