The fix using cartridge cases were a lot of work and they didn’t take solder well (or my soldering skills suck). Anyway I tried welding the two sheaths together to see how that might work. I squared up both ends that are to butt to each other and inserted the thick wire .077 dia. into the sheaths for alignment. I then tack welded the joint with three tacks using a wire feed welder. Worked perfectly and took only about ten minutes. Really easy!
As a note, in my research I found that the most common bowden cable uses a thick wire .077 which is quite stiff. It will work on the prewar speeditwins and fours but the postwar model need the thinner wire .054. The Dorman standard utility cable (Choke cable) #55196 uses the .054 wire.
