Bouchillon Kickdown Kit Modification

[Weldguy]

As my progress slowly continues on the "second resurrection" of my '70 Challenger R/T, the next item on my list was the installation of the Bouchillon Torqueflite Cable Kit. I must admit, I'm impressed with the quality and engineering of the kit. I don't mind paying a premium for quality.
As I was adjusting and fitting the components, I was concerned with the plastic cable end popping of the ball stud a few times as I moved things around. Once the TTI headers go on, there is virtually no way to get to the cable end if it were to pop off at some point.
I came up with a fairly simple "insurance policy" to prevent the plastic cable end from popping off. I thought some members who will or have installed this kit would be interested in my simple solution.
I took some measurements and checked the material inventory and came up with a piece of one inch thin-wall square tube that was perfect. After cutting one side of the square tube off and drilling a couple holes, I tack welded a nut on the top for the set screw. The set screw is adjusted so there is about a 1/16 inch gap between plastic cable end and the set screw. Check out the pictures below. They are pretty self explanatory.

 

[Weldguy]

AFTERTHOUGTH: If I were to make this again, I would have used a 1/4-20 nutsert instead of tacking a nut to it. That would look more professional.

 

[Katfish]

Interesting, the Bouchillon kit, while nice, is nothing more than a slight mod using a factory cable. I don’t see that popping off.
I’ve been using the same kit on my 518 for the last 10yrs.

 

[Weldguy]

Interesting, the Bouchillon kit, while nice, is nothing more than a slight mod using a factory cable. I don’t see that popping off.
I’ve been using the same kit on my 518 for the last 10yrs.

It popped of for me while I was fumbling with cable routing and checking under-hood locations and trial fitting. While it probably would not come off once installed permanently, I could never get to it if for some reason it did once the big 2" tube leaders were installed. I'm a retired engineer with 25 years of problem solving complex assembly issues. The prospect of the plastic part popping off intrigued me and it was a challenge to come up with something simple to assure it would not. My wife labels it my, "Automotive Obsessive Compulsiveness." LOL

 

[Katfish]

I completely understand, nice work.
Agreed the rivnut would be easier to fab and not have to weld.