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I hear you on the cost of things. I'd love to ship all three of my HS6s off to Rhys for rebushing and a full professional rebuild, but I can't afford the cost of one right now. I tried the rebushing technique as described by the Chicago MG club site and had mixed results.
Instead of rubber bands, I used some 5/16" ID nylon plastic washers to accomplish the same task. Got them at the local hardware store for a few cents each. They work well enough, but they do bind the throttle a bit at first. eventually they wear in and things settle down nicely. Soft copper washers are another option if you have the clearance.
I used a set of stacked O-rings and a copper washer in my HIF6 carbs. That works okay.
Regarding the need for bushings. Have you tried the simple worn bushing/worn shaft trick? I read about it in one of the british car supplier catalogs. You remove the butterfly plate and throttle lever and such then you withdraw the throttle shaft only slightly - just enough to get past the worn out spots. Then you check for play. If there is none, you just need shafts. if you still have play you need bushings (any maybe shafts too)
The best price I've found for HS6 throttle shafts is from "Victoria British" for $15.00 each (same shafts as for a Triumph TR4a).
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