clamping of throttle cable

I notice in your first link that you are using an AN3 bolt to clamp the throttle cable, instead of a M5 cap head bolt (as supplied by Rotax).  Did you have to drill a hole yourself under the head of the bolt?  I have seen a variant of AN3 bolts which have a hole under the head, but I cannot find the code.  Did you use such a bolt?  

Adam Dickson wrote:

I actually tried the solder approach (with plumber's flux) without success

Plumber's solder does have an aggressive flux, but it's formulated for copper or brass oxides.  Stainless steel forms a tenacious oxide layer that requires a very active zinc-chloride and acid based flux (example).

Using any acidic flux on a throttle cable wouldn't be a great idea in any case because acid can easily become trapped within the cable strands, promoting corrosion.  Worse, there's no way to tell how far up the cable it wicks during soldering.

The clamping system works fine. Just don’t remove the cable unless ithe end was twist welded before installing, unless you want to shorten it. If you’re removing the carbs I’d suggest removing the throttle arm.

You can use heat shrink on the cable ends to to protect them from fraying.  This is easy to apply and remove when needed. 

Hi Walt
Thanks for these links.  I like the stop idea.  I have noticed a couple of other things of interest.  You appear to be using an AN3 bolt to fasten the throttle cable.  Is there a variant which has a hole drilled under the head, or did you have to drill this hole yourself?  I am also interested in how you safety wired the choke cable sleeve.  My sleeve is just jacketed bowden cable, and the only way to hold it in place is with safety wire.  I am not sure what the "best" way of doing this.  Do you have any similar photos showing your method?
Thanks
Adam