Method of assembling a valve system during composite molding process

A method of integrating a throttle valve assembly with an air horn throttle body part comprising the steps of:

• first developing a core body adapted to be movable within a component part and consisting of a throttle valve shaft with at least one butterfly type throttle valve fixed thereon and extending transverse thereto;
• second, capturing the core body in a meltable core to envelope the body with a protective liner having an outer shape generated by the paths of movement of the core body with said liner having a thickness corresponding to a final clearance between said throttle shaft and said throttle body part;
• third, placing the covered core body in a mold die of the throttle body with which ti is to cooperate and rotate therein subsequent to being joined together as an integral assembly and molding the core body and throttle body together;
• and
• fourth, removing the integral assembly from the mold and heating the integral assembly to melt and remove the liner from the core body to provide the final clearance space between the throttle shaft and butterfly valve of the core body and the throttle body permitting relative rotation therebetween.