sasktrini:
"I showed my carbs to a co-worker. He's going to try to build up the shafts and then turn them down, rather than inserting bushings... going to try one of the Fords and the Holley. He was concerned about the relative thinness of the bushings compared to his suggestion... makes sense to me. Will see how it goes."
I rebushed my Autolite 1100 a few years ago. I have concerns about what your co-worker is suggesting - how is he planning on building up the shaft? If your shaft does not have a noticeable worn ridge that your fingernail catches on, I would strongly suggest bushing trhe carb instead. Note that the shaft is steel and the carb body is aluminum. Typically the carb body will wear much faster than the shaft. I would be concerned about the straightness of the throttle shaft after building it up.
Unfortunately, I did not take any pictures of the 1100 when I rebushed it. That carb was replaced by a Weber 32/36 a couple of years ago and I sold off the 1100 last year to someone on this list. I did take some pics where I did the same type of repair on the choke shaft of the Weber. I would suggest a sintered bronze bearing material -I may have used brass on the choke bushings. The first couple of shots are before pics:
http://i290.photobucket.com/albums/ll27 ... 190012.jpg
http://i290.photobucket.com/albums/ll27 ... 190013.jpg
This one is an after picture. Note: the bushing in this picture is actually a bit
thicker in cross section than what I did on the 1100 because the choke shaft bore was so badly worn on the Weber.
http://i290.photobucket.com/albums/ll27 ... 190015.jpg
I am not a machinist, I am more if a self tought metal working hack (who is fortunate enough to have some big toys such as a lathe and mill). My proceedure: 1. Using a long drill (that allows me to drill all holes from one side) & drill press, drill hole oversize. 2. Rough turn bushing so that the OD is a light press fit relative to the newly drilled open bushing with the ID about 0.015 undersize to the throttle shaft. 3. Press in the bushings. 4. Ream the bushings to size.
I am cheap an use an adjustable reamer and after every reaming iteration I test fit the shaft until it slips in with out binding. From memory, the throttle shaft is 5/16 dia. and if I needed to do several of these, I would buy a 5/6+ reamer. Notice that the bushing wall thickness is faily small.
On some list, I remember reading a message where someone mentioned that one could buy throttle shaft repair bushings. With that, the only power tool that would be recommended would be a drill press. Try a google search to see if you can buy bushings for your shaft diameter.