Throttle cable how-to

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Old 06-05-06, 11:13 AM
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OC_
I'm bastardizing my car!

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Throttle cable how-to

I dont know what you guys are doing for your throttle cable after your engine swaps. I know they have some after market ones intended for hot rods and such, but i found that you can cut your stock rx-7 one and adjust it to the length you need and then re-attach the metal stopper. The benefit of doing this over getting a universal cable is that you can use the oem grommets so it fits properly in your firewall. Also, I got the throttle cable that was for my engine so it connected to the throttle body perfectly.

For my swap, the cable needed to be around 8" long, much shortter then either the rx-7 or s2000 cable.

First, I cut off the metal stopper off thats on the gas pedal side of the original RX-7 cable. I removed the firewall grommet along with the plastic gas pedal connector and the rubber buffer.

Next, I cut the metal stopper off the gas pedal side of s2000 cable. You always cut that gas pedal side because you really cant redo it so it fits the throttle body again. So, do all the modifications from the gas pedal side.

Now, measure the length of the black outer hose that the cable goes though, and cut that to your desired length; before cutting, remove the inner throttle cable so you dont cut though that.

Now, put the throttle cable back into the black hose and but your grommet on as well. Then install the cable into the car like you normaly would. Connect it to the throttle body and everything. The actaul throttle cable should be too long and past your gas pedal. Measure that and make a mark on it where you want the end to be. Make sure that you measure the thickness of the plastic connector and rubber buffer and add that length to that measurement.

Now you have to reattach the metal stopper. This is where it gets tricky!
That metal stopper is made of a very soft metal, I'm guessing something like tin. So what your going to do is melt the old ones down and stick the new cable into the molten metal. But before you do this, place the gas pedal connector and buffer on your cable. then, you have to tie a knot in the cable right where you placed your mark on it; this is so that the metal wont pull off the end. Make sure you grip the cable with pliers and pull that knot tight. cut off the excess.

Your going to need something to melt this metal in. I used small copper water pipe end cap. I placed the old stoppers in the cap and melted it down with a propane torch. If you dont have enough metal, you can add solder to it. I think plumbers solder is stronger then electrical, so I used that. Now just stick your knotted cable into the liquid metal and let it cool. After its cool, pull the new stopper out of the end cap. If its stuck, you can cut a slit down the sides of the cap and peal it off with some pliers.

There you have it. Now you should have an OEM looking throttle cable for your engine swap!
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