However, I thought I had more line than I really did and ended up pulling it (pretty hard) to the point where the cylindrical head was stuck about an inch and a half in. I can't get much tension in the line to push it back out because the chainstay is so long that the cable folds in on itself before the cable head moves at all.
I've tried using a really small amount of contact adhesive to stick an allen wrench to it but that failed (I'm really hoping the adhesive didn't bulge out and seal in the cable). My next thought it using really strong epoxy (JB Weld) to stick a small cable to it and pulling it out - at this point I'm sure it's pretty well lodged in there.
Any ideas better ideas?
start with a small bit that won't skip as much/far to make a pilot hole, then enlarge it to a size that'll take the screw
if there's room, get a piece of stiff wire and try poking it in from the bb end to push the head out
freezer spray - but check first to make sure steel coefficient of expansion is greater than cf+epoxy
is the area the head is lodged in structural or a separate guide channel, if it's the latter you may be able to get a dental pick in there and gradually ease the head out
hope you find a good solution!
The smart thing to do would have been to use cable housing and put the opposite end of the shift cable through that and thread it through to where the wire is stuck. There would have been more than enough force there to push it back through. Of course I didn't think of that until after I'd tried contact adhesive and lodged it further up the tube. Really really hoping I didn't bond it to the frame.
At this point a dental pick wouldn't work either, I filled the hole with water and nothing goes through so it's a pretty tight seal...
put a bit of the glue on bit of metal foil, let it dry, see if white spirit dissolves it, for contact adhesive o think it will, if it does then put a few drops onto the stuck head let it seep in (it's also slightly lubricating until it evaporates) for 15-20 minutes, re-applying if it dries, then try using the outer to shove it out
white spirit is ok on carbon rims, so should be ok on a cf frame
you can also try to heat the inside of the chainstay to loosen the adhesive. Contact adhesive fails under heat.
Either with a heat gun or soldering iron or something.
If you had a soldering iron with a long tip (2inchs) you could heat the wire directly to melt the adhesive.
I'm looking into soldering irons, but having a hard time finding anything long enough (2 inches at least?). Acetone will dissolve super glue, but also the epoxy that holds carbon fiber together.
Does anyone know a carbon fiber safe super glue solvent?
It may be dremel time soon.
I now know that carbon fiber has a negative thermal expansion coefficient - so heating it would make it shrink (which would be ideal as it would make the hole minutely bigger, loosen up the superglue) but might make the steel expand to a greater degree??
that is what I used, I'm not sure what it is
Dremeling is much harder than I thought it would be, probably making it worse. I'm going to call a local carbon repair shop on Monday
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