brake line wear on toggles

[tetra316 0]

I had a new lineset put on my katana about 40 jumps ago. Hma line with the lower brake lines finger traped and bartacked at the factory. This doesn't allow for a knot to be placed behind the toggle like their pervious linesets so the line is loose on the toggle. Anyway I noticed this wearing on the line, it's cutting it in half. And in the same exact place on both brake lines. Called pd and they recommended I replace the grommets and they would send me a new set of lower control lines. Very attentive and awesome service by the way!!!!!! They think it's due to a rough grommet however it seems to me and my rigger that its also because the line is allowed to move all over the toggle on the side. So will get new toggles and see what happens. Anyway just wondered if anyone else had this happen to them from the new preset lines? Or maybe it's just me and my bad grommets.

[snafuhere 0]

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This doesn't allow for a knot to be placed behind the toggle

why not? I would put the knot to make the loop tight
looking at the picture it seems possible

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[hookitt 1]

Could you take a picture of it attached to the toggle? I've always finger trapped the loop ends with out using a knot so I'm curious how it's attached.

My grammar sometimes resembles that of magnetic refrigerator poetry... Ghetto

[seal_S49 0]

Without being able to inspect the toggles myself, the photos make me suspect that the sharp-edge grommet theory is correct. The line has to rub across something hard and sharp to cause that kind of damage. Sometimes the mfr's grommet tool is out of adjustment, causing grommets that are not fully set (compressed) with the unfinished edge still protruding. I've seen this type of defect before.

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will get new toggles and see what happens.

If you're going to replace the toggles only for that reason, I'd rather suggest asking your rigger to take his #0 grommet set and re-stake the old grommets. A bit of attention with some emory cloth may also be needed. Of course you'll also want him to replace the frayed sections of line (toggle to cat-eye). This is a chance to have your rigger finish these with any type of toggle attachment you prefer--a loop of any size or a knot in the running end. The entire job may cost less than those new toggles ($25 + shipping) and you'll need the line repair anyway.

[tetra316 0]

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This doesn't allow for a knot to be placed behind the toggle

why not? I would put the knot to make the loop tight
looking at the picture it seems possible

Not possible because the brake lines are preset and bartacked. If I put a knot in it then it makes the brake lines too short.

[tetra316 0]

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Could you take a picture of it attached to the toggle? I've always finger trapped the loop ends with out using a knot so I'm curious how it's attached.

See the second picture. The loop itselt is about 1 1/2 inches long but the toggle is probably only 3/4 inch wide hence the 'play'.

[tetra316 0]

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Without being able to inspect the toggles myself, the photos make me suspect that the sharp-edge grommet theory is correct. The line has to rub across something hard and sharp to cause that kind of damage. Sometimes the mfr's grommet tool is out of adjustment, causing grommets that are not fully set (compressed) with the unfinished edge still protruding. I've seen this type of defect before.

I would agree except I've put about 800 jumps and two linesets on these toggles and never had an issue before. That's why it makes me think it might also be because the loop is so loose installed. Of course maybe wear and tear is maybe causing the grommets to become deformed even though they look and feel fine.

[seal_S49 0]

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never had an issue before. That's why it makes me think it might also be because the loop is so loose installed.

You may have the answer there. If your other linesets had a knotted running end (or a smaller loop) instead of the newer (bigger?) fingertrapped loop, there would have been much less movement (friction/abrasion) of the line across the grommets to cause such wear. On the other hand, it's possible that the grommets have been marginal all along and only now exacerbated by the toggle attachment method.

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wear and tear is maybe causing the grommets to become deformed even though they look and feel fine.

It takes a huge amount of line-wear to damage a grommet. Look at all the abuse that slider grommets take before they finally need replacement. On the other hand, look at how much wear your slider grommets did to those old linesets. Although the photos look like the line has been exposed to something sharp, I must admit that under severe conditions even a good grommet will eventually damage a line.

The condition of the grommets can only be answered by someone who has inspected them. I'm putting my money on your rigger.

I'll bet you a pack-job that this problem will be solved when the grommets pass inspection and the toggle attachment is tightened.

[teason 0]

If you suspect a grommet, take a q-tip and rub it on the grommet in question. If the cotton on the q-tip stays intact, it probably isn't the grommet.

I'd also consider the possibility of velcro damage if you have velcro toggles. (couldn't tell by the photos).

Just a thought

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