Let the cutting begin......

[jayb]

You could maybe use some brass sleeves for the shaft, and drill the holes for the sleeves slightly oversize, then epoxy them in place while a straight throttle shaft is used to align them.  Let the epoxy dry with the throttle shaft in place and you should be good to go.

[cammerfe]

Very instructional! I believe Jay does that sort of thing by holding a beaver by the hind legs and persuading it to gnaw on the aluminum.

KS

[ScotiaFE]

Drill it then ream it. Hold the reamer in your mill and you should be able to get it pretty square.

[66FAIRLANE]

I have a plan but it doesn't involve a reamer. Remember the outer shafts are on bearings which will seal them. I just have to make sure the middle where it passes through the throats doesn't leak too much. As I am using stainless shafts I think a Teflon bush might be in order in this spot. It will stop the stainless 'picking up' on the ally, seal up and I can offset to take out any small misalignment I might have. That way I can attack the outers from each side with a clearance hole and bearing counterbore then spot through for the middle which will become the oversize hole for the Teflon bush.

Not set on it. Still thinking....more than one way to skin a cat.

[BB-63]

What you propose is doable.  The teflon bush concept works fine on all Whipple's marine dual throttle bodies.  They also start as castings with the throttle bores already there. - Garrett