Travis,

thanks for the info. Do you have a basket on that bike? Upon closer
inspection, I believe that contact between the housing and my rattan
basket caused the plastic to wear through which caused the rupture.
See a photo of the other spot where the housing contacted the basket:

http://www.flickr.com/photos/gernothuber/5548985681/

I will replace the right side housing shortly, since it shows the same
wear. I also swapped and turned the washers that came with the Silver
shifters so that the little hook now prevents excess lever travel:

http://www.flickr.com/photos/gernothuber/5548985783/

Cheers,

Gernot

On Mar 22, 1:44 am, Travis <travisbreitenb...@gmail.com> wrote:
> 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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