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olivers

Member Since: 19 Jan 2012
Location: Southern Scotland
Posts: 115

2007 Defender 90 Puma 2.4 XS CSW Zambezi Silver

Bonnet release cable connector boxy thingy, rubbish plastic?

Second time on my Puma 90 that this stupid little junction thingy fails — part of FSE500080, the bit you can’t buy individually, the little plastic box with a sliding connector that joins the two cable ends.

That thing is made from cheese! Well, it’s some sort of useless plastic, less than 1mm thick. If the bonnet mechanism is a bit less than buttery smooth, a ridge of plastic eventually breaks off the little slider.

Can I get one made of metal somewhere? Or are there ingenious ideas how to make a connector from something solid?

I’ve already got one extra cable sitting on the shelf from a few years ago when the exact same thing happened and a whole new FSE500080 was sourced to replace one 20x6x6mm bit of plastic.

Last edited by olivers on 25th May 2023 8:36pm. Edited 1 time in total

25th May 2023 6:43pm

Dinnu

Member Since: 24 Dec 2019
Location: Lija
Posts: 3414

2012 Defender 90 Puma 2.2 CSW Santorini Black

Do you have a picture of what breaks?

I wonder if something from another brand, like from VW 1K2 823 535 A can be fitted. Never had one fail on my VW, but never had the Puma one fail either! 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black

25th May 2023 8:34pm

olivers

Member Since: 19 Jan 2012
Location: Southern Scotland
Posts: 115

Didn’t take a picture, I can grab one tomorrow. This problem is not new, has been discussed here before… without better solutions though! For instance here: https://www.defender2.net/forum/post167435.html

The cable ends look like this:

There is that plastic box that you see in part photos of FSE500080, both cable ends go inside. Then there is that sliding piece of plastic which has slots for the two end pieces. But that plastic is thin and brittle and eventually breaks.

I’ve come across the term “Bowden cable coupler” and there seem to be some online shops specializing in this type of hardware, but I haven’t seen anything that could serve the purpose here.

25th May 2023 9:39pm

olivers

Member Since: 19 Jan 2012
Location: Southern Scotland
Posts: 115

For illustration, here is a 3d printing model that is similar to the part inside the outer case: https://www.thingiverse.com/thing:381034

I doubt that a printed part would be solid enough, but then I’ve only ever owned pretty bad 3d printers… just happened to come across this.

25th May 2023 9:48pm

Ianh

Member Since: 17 Sep 2018
Location: Essex
Posts: 1997

Worth giving speedy cables a call, they may well have a metal joiner or can make up a single length cable for you.

Main site https://www.speedycables.com/
Light duty cable page https://www.speedycables.com/light-duty-cables/

26th May 2023 12:47am

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