Originally posted by Derk2000:
Any pointers? Wish me luck!
Leave the throttle plate in tact while doing the grinding, it will help you avoid the "no no" zone. Use a metal removal bit, not a grinding stone if you can help it. If you must use a stone, use grinder's grease to keep the bit from clogging with the soft aluminum. After the grinding, use sand paper rolls and a polishing bit to complete the package. Take apart the TB and bring the throttle plate bar along with you to ensure you get the right thread on the screws. To ease removal of the throttle plate screws, secure the TB on a bench with some drywall screws (make sure to hang the linkage over the edge) and get a cordless drill with the correct screw driver bit. This way you can get enough pressure on them to come right out without stripping... That should be about it. I just did three more on Sunday (have a little bit more polising to do before they're complete) and these are the only issues I can think of at the moment. Takes about an hour of work on the TB itself, plus removal and installation time from/to the car. Be sure to remove the TPS and set aside... waaaaaay aside as you don't want any metal in there at all. TPS's are about $30-$40 to replace...
Oh, and good luck!
