firstly stripped the thing down and strapped her down to the machine bed, i bored it out to 57mm up 3mm from the standard 54mm.
next came making the throttle petal, the first thing to do was to calculate the angle of the thing as it's not round but eliptical. i measured it and measured it then estimated it and ended up coming to the angle of 14
degrees, at this point i noticed that there was a number stamped on the front of the petal, funny enough it was 14. ah well i wasn't to know, but it was nice to confirm it anyway.
so on to manufacture, firstly i turned down some aluminium bar 57mm, next came to machine a 14mm angle into the face of the bar, once this was done a 3mm sliver of it was cut off in the band saw at the approximate correct angle. this was then skimmed to a final thickness of 2mm and cleaned up and finely deburred syill leaving a tidy sharp edge.
here you can see the finished product next to the original, with the all important now eliptical shape and the edges cut to fill the form of the inside diameter fully and neatly.
next came the fitting of the thing and assembling the nightmare like springs that clip and attach to everything and catch your fingers continuously, i knew i should have paid more attention when i took it apart
anyway heres the finished product all finished and fettled with a nice tight seal all round the butterfly.
I'll be fitting it in the next few days and will let you know if it makes any difference.
Kev
