TPS adapter

I spent the last couple of days working on the adapter plate and the post adapter to make the Ford TPS fit onto the Suzuki throttle bodies. After all that, I think I am going to hack the end of the Suzuki connector up, and solder some leads to the pins.

The plate worked well, it was simply a plate to adapt the 2 screw holes on the throttle bodies to the 2 holes on the TPS. The post adapter was really what was causing me the biggest issue. I started off with a 1/2" bolt cut to length. Then I tried to file the diameter down to fit into Ford TPS, and cut 2 slots along the length.

Not having a lathe, the diameter reduction didn't work out the straightest. And the slots were not the absolute right size. The steel bolt was extremely difficult to work with with simple hand tools. To make it easier, I switched to Delrin. If you have never worked with Delrin, you need to. It is a highly machinable plastic, with very nice characteristics in mechanical applications.

I was able to throw a post adapter together pretty quickly. It still wasn't right though. The slot was just slightly off of center. This caused the throttle to bind when opened anymore then 25%. It would open fine, but then it wouldn't return to closed. This worried me enough to think that I should probably use the original Suzuki TPS to avoid any possible problems.

The solution that I have come up with is to solder some wires to the end of the leads, shrink tube them, and fill the whole thing with epoxy. This should be easy enough to replicate if I were to ever need to replace it, and it should yield a professional look, and sturdy product. It's just going to need some fine craftsmanship to pull off the professional appearance. I think I can handle it.