Project started December 2020,
See the CAD version here

 
 
 
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Because of the sharp bend in my handlebars it would have been quite a challenge to get the throttle cable for the internal throttle in there, even though there is actually a rounded cable guide inside that sharp corner. An old trick I like to use is to superglue a piece of thread to the inner cable and blow the string through with compressed air. This works very well, then carefully pull the inner cable through. Then finally slide the outer cable over the inner cable (from the other direction)

 

For the little throttle linkage on the carb that I have been making, the tiny balljoints finally arrived and it turnrd out the dimensions were different than stated on their website. These are used for the suspension of RC cars by the way. Rather than re-order and have to wait again, I modified the "fork" that I had made, and with the help of Aad increased the diameter of the holes in the balls. Aad glued them to some aluminium bar and then carefully drilled out the holes!

 

The little part where the throttle cable will attach was actually printed in stainless steel, in this case it cost around €100 but it would have taken several hours to fabricate and I wanted to see what quality was achieveable in printed stainless. I was not disappointed! Printed stainless has a matte finish but turned out to be quite easy to polish. After assembling all the parts for the first time I found that the printed arm hit the frame, so I extended the pivot a few mm, all good now. I made the outer support from a piece of scrap metal and tack welded it in place for testing. I also added a return spring but forgot to take pictures of that. There is a post on my Instagram where you can see how it works though

 
 
 
 
 

To be continued...

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