Well, many have done it. You will see high idle, and retarded timing, maybe even glowing headers/manifolds.
1. Remove black plastic cover over the motor/gears.
2. Remove the middle gear, dont worry about position, doesnt matter
3. Rotate the throttle blade, and notice where the plastic stopper
hits the aluminum housing. Start with removing the aluminum.
4. Remove a little aluminum with a dremel tool and you will see blade close
some. If you run out of aluminum, you can remove some of the plastic.
Just dont remove too much plastic to the point of weakening it.
5. Re-attach and monitor comanded throttle until you see higher numbers
than zero, mine is usualy 7-12ish. You will also see your timing come back
6. Repeat till acomplished, assemble cover, then end, else go to step 7
7. If your here you really really really ported too much, get out the filler/bondo
8. Smooth a very thin coat of filler and sand smooth with 220, 330, 400, 800
NOTE, if you don't want to use filler, you can do multiple layers of acid etching primer
9. Inspect gap, and sand areas until they are even all the way around,
and closer by middle. You can do this from front to back of TB to
make it an even diameter all the way through.
10. When you are happy with your fill level, Paint with acid etching primer,
and apply quite a few coats (Even more if not using filler)
11. Sand with 330, 400, 600, 800, 1000, 1500, 2000, 2500, even 3000 if you
want too. Keep going until its smooth as glass, when your done it will
be better than polished alluminum ever could be.
12. Repeat steps 7-12 until your happy, assemble cover, and your done.
If you dont want the ugly green primer look, you could paint the color of
your choice, then clear coat several coats, then repeat the sanding process.
Good luck with your fix!!
1. Remove black plastic cover over the motor/gears.
2. Remove the middle gear, dont worry about position, doesnt matter
3. Rotate the throttle blade, and notice where the plastic stopper
hits the aluminum housing. Start with removing the aluminum.
4. Remove a little aluminum with a dremel tool and you will see blade close
some. If you run out of aluminum, you can remove some of the plastic.
Just dont remove too much plastic to the point of weakening it.
5. Re-attach and monitor comanded throttle until you see higher numbers
than zero, mine is usualy 7-12ish. You will also see your timing come back
6. Repeat till acomplished, assemble cover, then end, else go to step 7
7. If your here you really really really ported too much, get out the filler/bondo
8. Smooth a very thin coat of filler and sand smooth with 220, 330, 400, 800
NOTE, if you don't want to use filler, you can do multiple layers of acid etching primer
9. Inspect gap, and sand areas until they are even all the way around,
and closer by middle. You can do this from front to back of TB to
make it an even diameter all the way through.
10. When you are happy with your fill level, Paint with acid etching primer,
and apply quite a few coats (Even more if not using filler)
11. Sand with 330, 400, 600, 800, 1000, 1500, 2000, 2500, even 3000 if you
want too. Keep going until its smooth as glass, when your done it will
be better than polished alluminum ever could be.
12. Repeat steps 7-12 until your happy, assemble cover, and your done.
If you dont want the ugly green primer look, you could paint the color of
your choice, then clear coat several coats, then repeat the sanding process.
Good luck with your fix!!
