Oh oh oh! I had exactly the same thing happen in the exactly the same
way with some brand new Jagwire derailleur housing, I mean exactly. I
believe it just has to do with the way derailleur housing is built.
The strands of wires inside are all running parallel to the cable, and
if you put enough tension on the cable at a bend it will pull through
those strands in order to straighten itself.

To prevent repeat episodes, I set my front derailleur shifter up so
that it is physically restricted by the shifter pod at the exact point
at which the front derailleur is hitting the limit screw for the big
ring. So, when I'm in the big ring my bar-end shifter is pointing
upward, and when I'm in the small ring my shifter is parallel to the
ground. I don't think it looks quite as nice this way, but I got over
it quick and never have to worry about busting the housing.

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