Hydraulic Couplers - Tool/Approach suggestions

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Calps
Posts: 10
Joined: Wed Oct 25, 2023 9:30 pm

by Calps

Hi folks,

Hoping the hive mind can suggest a suitable tool/tools (or alternative approach) that I can use to manage the following:

I've purchased some zeno q-connectors to allow hose disconnection for travelling and servicing: https://zenocycleparts.com/collections/ ... ck-coupler

Image

The connection point for the couplers will be at the stem/fork junction, with cables being routed internally through the stem and down into the frame.

The pressure required to close the couplers together is enough to require both hands, which means I've no free hand to apply the retaining pin. It's manageable in practice, however the challenge is exacerbated by the small space to work within between the stem exit hole and the fork entry point.

I'm wondering if there is a tool in existence that could clamp each hose end and, similar to a master link pliers, pull them together in the small space?

(NOTE: I'm leaving enough slack in the lines to be able to remove the stem from the fork so won't be a tiny working space, however it's only a few cms, and so the stem and bars still need to be balanced somewhere nearby, and as I plan to use this for when I travel, I'm envisaging a situation where I'm trying to do this in a hotel room, where I won't have tools, bikestands, etc.)

Any and all suggestions would be welcomed!

by Weenie


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Nickldn
Posts: 2241
Joined: Mon Mar 25, 2019 12:35 am

by Nickldn

GF/WAG :D

Discodan
Posts: 416
Joined: Mon Oct 16, 2017 2:55 am
Location: Sydney

by Discodan

I’ve recently built up a travel bike using Zeno couplers and have exactly the same issue so am keen to see if anything comes up in this thread. I wonder if a plier with a machined slot or 3D insert to grab the fitting would work. The challenge is the pin side has quite a small setup in diameter so the tolerance would need to be fine, and the opening (ie the distance between the two engagement points) is a fair bit more than more pliers.

I’ll do some poking around, it feels like there will be some type of specialist pliers that might be easily modified for the job


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Discodan
Posts: 416
Joined: Mon Oct 16, 2017 2:55 am
Location: Sydney

by Discodan

I wonder if these will work, designed for holding wire whilst it’s soldered but I think it would hold the hose nicely. I think for $16 I’ll give it a try

https://www.ebay.com.au/itm/18596227872 ... FCWXQZRC80


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Calps
Posts: 10
Joined: Wed Oct 25, 2023 9:30 pm

by Calps

Discodan wrote:
Sun Apr 28, 2024 1:22 pm
I wonder if these will work, designed for holding wire whilst it’s soldered but I think it would hold the hose nicely. I think for $16 I’ll give it a try

https://www.ebay.com.au/itm/18596227872 ... FCWXQZRC80


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Thanks Discodan, interested to hear how you get on with those pliers. I would worry that the clips on each end may not have the resistance needed to hold the hoses in place without slipping, however I guess you could cable-tie the hose to keep it secure, and then snip them off afterwards. (I considered something similar with just a "normal" pair of pliers, but coudln't get everything to hold in place long enough).

For now, I am attempting to increase the amount of hose slack I have to work with by unbolting the calipers, and also using the 3d printed stem spacers that came with my EXS bar (which have an opening on one side, and can be easily slid onto the fork without removing the handlebars). The main hurdle is feeding the couplers back up into the handlebars when reassembling without kinking the hoses.

The other challenge is finding a solution that works, before I start cutting hoses to length. The xeno couplers I got were those which were already clamped onto the hose. I don't think I can swap out the hose, so if I get the length wrong, they become redundnat pretty quickly!

Discodan
Posts: 416
Joined: Mon Oct 16, 2017 2:55 am
Location: Sydney

by Discodan

Hi Calps,

The pliers kinda work but not a great solution as, particularly with the pressed on pin options from Zeno which are very slim, there's not enough 'lip' to reliably grab as you say.

I have found a much more elegant solution though which seems to work well with initial testing. I've added a short length of stainless lockwire to each coupler with a small loop that can be grabbed by the pins on a set of chain connector pliers, which then pull both ends together nicely. It works best if you push it into place with your hands and then use the pliers to hold it closed with one hand whilst you put the clip in place with the other. If the coupling was exposed you might want to think about taping it up to hide the wire but for me the couplings are in the frame and under bartape so it's not a problem.

If I can get the photos to work, this is what it looks like. [can't embed them from here, will try later, but you can click through to them]

https://1drv.ms/i/s!AlR9KEiul8ImhLJPwAJ ... A?e=qFVZUQ
https://1drv.ms/i/s!AlR9KEiul8ImhLJNeEs ... w?e=5P2MYp

by Weenie


Visit starbike.com Online Retailer for HighEnd cycling components
Great Prices ✓    Broad Selection ✓    Worldwide Delivery ✓

www.starbike.com



Discodan
Posts: 416
Joined: Mon Oct 16, 2017 2:55 am
Location: Sydney

by Discodan

Take 2ImageImage

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