BDL Industries is no newcomer to the sport compact market, having been around in some form or another for quite some time. You may even have some of their parts without even knowing it.
BDL started as Belt Drives Ltd. and used to produce parts for aftermarket operation STR, but eventually parted ways. Following that chapter, BDL came up with its own line of products and now has the facilities to manufacture and ship them. Located in Orange, Calif., BDL Industries consists of an aluminum foundry and other buildings that house over 50 CNC and lathe machines. With these tools, BDL is able to design, manufacture and test their line of products in order to ensure that the utmost quality and care is being put into each product that is made.
Although BDL makes products as diverse as cam gears, fuel rails, fuel pressure regulators, and oil caps, we asked them for a tour to show us how they make their throttle bodies. Nick Winters, general manager at BDL Industries, gladly did the backwards walk-n-talk, illustrating how one of their throttle bodies goes from concept to reality.
 No big surprise, the first...  No big surprise, the first step in making throttle bodies is research and design. Each TB is designed using the SolidWorks 3D CAD program. This program enables BDL to input their unique desired specs for each throttle body and create a 3D image of what each will look like. |  After the design is complete,...  After the design is complete, the specs are entered into a type of rapid prototyper that creates a plastic mold of the throttle body. Shown here, the prototyper generates layers upon layers of plastic as they eventually form the shape of a throttle body. The plastic mold is then test fit on the vehicle to check for clearance issues and fitment. If it does not fit to the required specs, it's back to the drawing board and another plastic mock up is made. |  After the throttle body's...  After the throttle body's design and fitment are up to par, the machining process begins. BDL uses 6061 grade aluminum that comes to them in 144-inch bars. The bars are sent to BDL's mill building where the CNC machines cut the bars to form the front and back of the throttle bodies. After they are formed, the throttle bodies are sent to the lathe building to have the inner bores cut out. After the CNC machining process, the aluminum casting is sent out to be anodized in order to give it the proper color and finish. |
 Once the throttle body is...  Once the throttle body is anodized, it goes back to BDL's mill building to get the logo engraved into it. The anodized finish gives it a gunmetal look. The throttle body is then assembled with the proper equipment to accommodate the OEM provisions. |  Attention to detail is key...  Attention to detail is key during the assembly process, as Carlos Carillo shows us how he assembles the throttle bodies. Roller bearings are first pressed into the sides of the throttle body so that the when the shaft that secures the butterfly is put in later, it can move with ease. Rubber seals are put in next to ensure that there are no air leaks and also that the shaft is held in place. When these components are in, the other major parts can be assembled. |  As you can see, the rubber...  As you can see, the rubber seal fits perfectly around the shaft, preventing any would-be leaks. Shown here, Carillo screws the butterfly onto the shaft. BDL's throttle body butterflies use a chamfered edge to prevent them from sticking to the walls of the inner bore during operation. After the butterfly is attached, the Throttle Position Sensor (TPS) boss is secured with screws and Loctite, as well as any other holes that need to be screwed to keep the throttle body together and prevent any air leaks. As part of the development process for their throttle bodies, BDL tests each one repeatedly to make sure that the butterfly does not stick due to aluminum expansion at operating temperatures. |
 BDL uses a double-wound spring...  BDL uses a double-wound spring that is strong enough to take all kinds of throttle abuse. This spring modulates the opening and closing of the butterfly and provides tension to the throttle cable wheel when the gas pedal is pressed. |  The excess wires are cut off...  The excess wires are cut off and the cable wheel is put on.The throttle cable is secured to the spring, completing the assembly process of the throttle body. |  When the throttle bodies are...  When the throttle bodies are completely assembled and ready to go, they are shrink-wrapped and boxed up to be sent out. BDL's shrink-wrap machine secures the throttle bodies in such a way that the consumers should dedicate about 30 minutes of their time just to open it. After all, a good quality product deserves good quality packaging. |