Throttle Control and Handlebars Part 1

The throttle twist grip assembly is a two cable unit. The housing halves were in good shape except for severely pitted chrome on the top half.  

I was considering rechroming, but I found an entire new "reproduction" assembly for a pretty cheap price. The finish on the repro housing (on the right) is not great, but a lot better than the original. I still wasn't too unhappy with the purchase.

But here are the kinds of things that really irritate me about some "reproduction" parts. First, on the grip "rotor", the recesses that accept the barrel ends of the throttle cable wires are too small to accommodate the nominal 1/4-inch barrels. Just drilling them won't work because they are too close to the main bore and would probably break through. Also, the track that holds the wire from the barrel won't allow the wire to come into the barrel from the side, which would put a kink in the wire right there. This part is useless to me, but luckily, I can use the original.

Next, the original "cable stops" (on the left), which hold the ends of the outer cable sheath are a nice slip fit for the ends of the cables. The replacement items have quite a bit bigger bore for a sloppy fit. Again, luckily, I can use the originals.

Finally, the screws on the replacement unit are different from originals. The original screws holding the two halves of the body together are 1/4-26, while throttle stop and the friction screw are both 7/32-40. Granted, these are both oddball threads, at least in the States, being British Standard Cycle (BSC) and Model Engineer (ME) threads, respectively. The new screws are M6-1.00 and M5-0.80 metric.  

Now I am not really all that anal about originality, but since I plan to keep this bike, I'd like to keep it in comformance with the parts catalog as much as possible, so that parts I or someone else orders for it in the future will still fit.