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The World's Lightest & Strongest Control Cables...

The World's Lightest & Strongest Bicycle Cables.

Tony DuPont was the Lead Floor Manufacturer for SEP Global Technologies before he left the corporate world to be an entrepreneur. It was a lay-off that spurned his entry into the cycling industry with a never-before seen control cable now sold world-wide and used by professional racers.

PowerCordz™ and Io DuPont, the company that would develop the world's only synthetic fiber bicycle control cables selling in the market today, started in a garage in Boise, Idaho in 2004. By then, the idea of using synthetic fibers to replace steel in bicycle cables had been around for some time. Several well-known bicycle component manufacturers had dedicated research and development to the idea but never found the right design to make them work. When Tony DuPont heard of the synthetic cable concept, he made it his mission to follow it through to the end and; that's exactly what he did.

"I researched and researched to find just the right type of fiber and eventually found Zylon®," remembers Tony. "I didn't know anything about the types of materials we now use when I first started." The cord that Tony ordered for his first experiment came as a braided rope - far too thick to pass through any conventional bicycle cable housing. So, Tony took it apart, un-braided the rope, grabbed a bucket of grease and started working it into the fibers to hold them together. He then pushed (with no shortage of frustrations) the Zylon® fibers through the housing that came with his bike, tied knots to his brake levers and pads and went for a ride. It was a special moment and when the real work began.

Tony had his fibers but still had to figure out how to attach them. After all, tying a slick piece of greased up Zylon® to a brake lever isn't exactly a marketable product. He used every bit of his education in mechanical engineering to design an adequate anchor. He made a testing jig he called "Big Bertha" to use in trying potential models. Unfortunately, "Bertha" had a resting load of 50lbs-- making it so an anchor had to be at least that strong before it would even stay on. There was a long period of time when he couldn't get anything to hook up. Finally, the anchors were strong enough to hold 60lbs, then 100lbs, then 150lbs. By 2005 the technology was in place to anchor a small dimension synthetic cable that could hold more than 600lbs and fit standard bicycle components. The University of Idaho and Boise State University both tested the cables in their materials labs to get a full picture of how synthetic cables perform in the long run and under harsh conditions. At last, after more than a year and a half in development, it was time to bring Power Cordz™ to cycling's racers and enthusiasts around the world.