I've done a bit of improvising with the throttle racks, as it looks like they might be quite hard to get hold of I thought in the mean time I'd have a go at making some
This is the piece of nylon I started off with, bought it online for £10 and as its probably enough to make about 10 of these so it will work out pretty cheap IF it works.
I set about cutting a block to the right size (carefully as I've found out just how easily nylon melts when you cut it) and putting a groove in the back of it so it follows the channel in the case casting.
Next I "roughly" drew around the teeth on the throttle lever moving the nylon block along as I went to try to keep them inline.
Then finally cut out the teeth. I tried doing this initially with the Fein saw but soon gave up when things started melting so I ended up using the chop saw with the head set to an angle of 7.5 degrees which is roughly the angle of the side of the tooth. I set the depth stop so it was about the right height and cut each tooth, two passes from each side to get the V shape of the tooth.
Thats how it came out after a bit of adjusting making each tooth equal etc there is still a bit of tidying up to do with a file but it's almost there. It seems very strong and slides well with the lever so fingers crossed, the only thing left to do is drill a hole down the center to accept the cable but until I've got hold of one I'm unsure of size and location so I'll leave it for now.
