Old front cable was frayed around the nut and starting to unwind. Original nylon ferrule on the brake lever had seen better days and was allowing the outer to lean to one side.
The hole in the top of the alloy brake lever is too wide for the Jagwire ferrule to sit in, so it needed adapting into the original nylon one.
First I took the nylon ferrule and bored the centre-hole out to 6mm. The diameter of the thinner part of the shank on the Jagwire ferrule is 5.5mm, so the hole was slightly too large in the nylon and only left about 1mm sidewall.
I used strong epoxy resin to both fix the Jagwire ferrule in place and to reinforce the nylon ferrule. With a coat of black paint it looks quite smart and fits snugly back into the alloy brake lever, with the outer cable sticking straight up, as it should. Obviously, the ferrule is not fixed into the brake lever with anything, it is completely removable.
The original steel ferrule holding the outer on the head-stock bracket is held by an 8mm nut either side and snapped with hardly any force. This left a 5mm hole in bracket, not quite wide enough for the Jagwire ferrule. A benefit of the alloy ferrules in the upgraded stainless-braided Jagwire kit over the plastic ones, is that I was able to use an M6 die to thread the lower part of the shank.
This meant I could then bore out the hole in the head-stem bracket slightly and tap it to M6 thread as well, allowing the ferrule to screw directly into it. This not only solves the problem of fixing the ferrule in place, but I also think a larger hole in the tiny alloy bracket might weaken it too much.
It works fine in practice. Shame I couldn't thread the alloy ferrule all the way down the shank without damaging it, but it still just about has enough to come through the lower side of the bracket and seems pretty solid. The outer cable is straight again and looks a lot tidier.
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