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Here's the stock POS that we'll be working with. Our goal is to fill in that huge cut out area at the top, remove some material near the throttle blade and at the front lip of the body, and get us a true wide open throttle opening.
First off, you need to mark the throttle body at the blade with a marker so you don't be sure to go past the blade into the back side. Go too far and it'll cause all kinds of idle problems and weird chit. While you're at it, mark the shaft at each end where it goes into the body, like in the pic below. You can see both marks.
Now disassemble the entire thing. Remove all the connectors, unscrew and remove the blade, and remove the shaft. After you take off the tps, you can simply whack the shaft out with a hammer. Don't feel bad, it won't hurt anything. ***Pay attention as there is a very small washer that will fall out on the tps side too, do not lose this!!***
Now you need to fill in the cut out area that goes into the idle air bypass. I used 2 pieces of stanless tubing inserted before I filled it with Bondo. You can simply drill the holes later if you need to. I also put a piece of aluminum can against the opening and cut out 2 holes for the stainless tubes to slide through. This way the Bondo wouldn't completely fill the cut out area and choke it off.
While that's drying, go ahead and knife edge the throttle blade. I used a bench grinder, but you can use the dremel if you choose. Also, round the back edge of the blade off...airflow off the back is as important as the front.
Now move over to the shaft and get ready to cut it. What you will be doing is cutting off the front portion that you see when looking at the throttle body head on. When the blade is opened up this makes a big bump and a big restriction. Reference the marks you made before you took it apart and cut there.
The shaft will look like this now:
Once the Bondo or your metal filler is dry, time to start porting. It will take a while, but be patient and be careful, making sure not to go too far into the throttle body (keep an eye on the mark where the blade will sit). Knife edge the leading edge of the body and grind back to your mark. Pay attention to the area near that mark, as there is a "lip" right there that is a major obstruction to air flow. You are able to feel it with your finger. Your rough cut should look something like this (if you didn't use the stainless tubes, that area will be solid filler):
Be sure not to go past your mark!!
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