Motion transmitting remote control assembly and method for making same

A motion transmitting remote control assembly of the type for transmitting forces along a curved path by a motion transmitting core element, said assembly comprising:

• a flexible conduit (14);
• a flexible core element (30) moveably supported by said conduit (14) with a slug (34) fixedly secured to one end of said core element (30) for movement therewith;
• a shaft (22, 22') defining a channel (32, 32') therein with an opening (37) at one end thereof for receiving said slug (34) into said channel (32, 32'), said channel (32, 32') including an engaging wall (33) disposed oppositely of said opening (37) in another end of said shaft (22, 22'), said engaging wall (33) having an aperture (35) therethrough for slideably receiving said core element (30) into said channel (32, 32');
• a plug (38) disposed in said opening (37) for preventing escapement of said slug (34) from said channel (32, 32'), said plug (38) including a shank portion (39) extended into said opening (37) and dimensioned for a press-fit within said opening (37) to resist inadvertent removal, said plug (38) including a cap portion (41) positioned over said opening (37) to limit the insertion of said plug (38) into said opening (37);
• a plurality of longitudinally spaced annular barb-shaped projections formed on said one end of said shaft (22, 22') presenting annular planar surfaces (44);
• and a terminal member (46) molded to said one end of said shaft (22, 22') about said cap portion (41) of said plug (38) and said opening (37) and about said annular projections of said shaft (22, 22') defining mating surfaces (48) mating with mating surfaces (44) of said shaft (22, 22') for interconnecting said terminal member (46) and said shaft (22, 22') to prevent relative movement therebetween, said terminal member (46) including a flange portion (50) having a hole (52) therethrough adapted for connection to a controlled member.