I think that the worn area of the throttle bore could be repaired quite nicely with J B Weld.  I'm not sure about end-play, but the shaft clearance should be as snug as possible with no binding.  
  Also, I can re-bush the throttle shaft, if it's 8mm.  I've been overhauling and re-bushing VW carbs of all types for many years (they're all 8mm).
  BTW, if anyone can help, I do need to locate a source of the brass bushings, as I'm beginning to run low on stock.  My supplier went away over 10 years ago, but I still have enough to do a few more before I totally run out.
  I'm not far from you, David.  I work in the Providence area, daily. also.

Mike B.
  ----- Original Message ----- 
  From: David Beierl 
  To: vanagon@GERRY.VANAGON.COM 
  Sent: Saturday, March 14, 2009 8:15 PM
  Subject: Re: 2.1l throttle plate question

  I wrote:
  >Two questions, O all wise...
  >1) Should the throttle plate be bent at the centerline, or flat?  I
  >have bent, but I'm thinking what's wanted is flat.

  Well, no, what I have is thicker on one side so from the outside it
  looks bent.  What I also have is a nice worn ring around the inside
  of the throttle body.  It looks as though enough extra air is getting
  around there to explain why the idle-setting only barely comes down
  to spec with the adjusting screw fully in.  I wonder what would work
  to build that back up to its original dimension.  It would have to be
  oil-resistant.

  >2) How much end play of the throttle shaft is considered acceptable?

  I'm still curious about that.

  >Thanks much,

    --
  David Beierl - Providence RI USA -- http://pws.prserv.net/synergy/Vanagon/
  '89 Po' White Star "Scamp"