Bob Borger throttle cable kink 5.
"The squared end of the wire will be very difficult to run through the cable sheath.
So a jewelers file was used to round the end of the wire."
One option I may look at if the time comes I need to, is using next size thicker cable and housing as used on motorcycle brake and clutch. Or more strands than 1 and thicker than stock diameter, (McMaster sells stranded cable).
Y9-07-26