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Step 6Make the Release Assembly
A bicycle brake cable will be used to pull out the washer, but the housing for the brake cable needs something to mount to and push against.
Grab a piece of scrap 2x4. It can be less than 6" long. Using the finished reduction coupler as a guide, draw a sort of L-shape on the wood. The entire L-shape should be about as long as the entire coupler. The base of the L-shape should be about as long as just the wider section of the coupler. Make sure that everything is sized thick so that it stays strong.
When the pattern has been drawn on the wood, you can cut it out. I used a scroll saw, but a band saw or even a table saw would work. Cut just the main shape of the L-shape first; don't cut out the corner that makes it an "L" just yet.
Hold the semi-complete assembly in place on the coupler, and estimate where the hole for the cable will need to go. It will be in the center of the wood, a centimeter or two from the end. Mark this with a pencil.
Start with a bit just large enough for the brake cable. Drill a hole down far enough that it passes all the way through to where the corner will eventually be cut off. Now, select a different bit that is just large enough for the brake cable housing. Using the depth gauge, drill a hole about halfway to 2/3 into the top of the assembly, but NOT all the way to where the corner will be cut out. You must leave a bit of wood there for the cable housing to rest against.
With both holes drilled you can cut out the corner of the release assembly.
There is just one thing left to do. Using the edge of the coupler as a guide, draw an arc onto the release assembly where it will eventually mate with the coupler. Use this mark as a guide, and cut out the curve on a saw (this is where a scroll saw really comes in handy). When cut, the assembly should sit flush against the large part of the coupler.
Grab a piece of scrap 2x4. It can be less than 6" long. Using the finished reduction coupler as a guide, draw a sort of L-shape on the wood. The entire L-shape should be about as long as the entire coupler. The base of the L-shape should be about as long as just the wider section of the coupler. Make sure that everything is sized thick so that it stays strong.
When the pattern has been drawn on the wood, you can cut it out. I used a scroll saw, but a band saw or even a table saw would work. Cut just the main shape of the L-shape first; don't cut out the corner that makes it an "L" just yet.
Hold the semi-complete assembly in place on the coupler, and estimate where the hole for the cable will need to go. It will be in the center of the wood, a centimeter or two from the end. Mark this with a pencil.
Start with a bit just large enough for the brake cable. Drill a hole down far enough that it passes all the way through to where the corner will eventually be cut off. Now, select a different bit that is just large enough for the brake cable housing. Using the depth gauge, drill a hole about halfway to 2/3 into the top of the assembly, but NOT all the way to where the corner will be cut out. You must leave a bit of wood there for the cable housing to rest against.
With both holes drilled you can cut out the corner of the release assembly.
There is just one thing left to do. Using the edge of the coupler as a guide, draw an arc onto the release assembly where it will eventually mate with the coupler. Use this mark as a guide, and cut out the curve on a saw (this is where a scroll saw really comes in handy). When cut, the assembly should sit flush against the large part of the coupler.
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