Good info here. I will be using this in the very near future so I appreciate the addenda. Any pics of the fabbed TPS bracket?
Glad I could help. This is a totally fair request and I have updated the pics accordingly.
There are probably a bunch of ways to make this bracket. My setup is a bit cumbersome. I originally tried welding small #10-32 nuts to the adapter plate but I found that the nuts themselves got in the way of the TPS Sensor. My setup also allows you to use BOTH throttle body mounting holes.
Here are my thoughts:
1) Use the thinnest metal you can find. I used scrap door metal skin given to my by a body shop.
2) For the two screws that will hold the adapter plate to the throttle body, you need #10-32 screws. That's the superfine thread (you can find this at an ACE Hardware). You also need as flat a head on the screws as possible to minimize the distance from the throttle body to the TPS sensor (hex shaped heads would minimize stripping BUT won't fit between the plate and the TPS Sensor).
3) Drill bigger holes in the plates so you can move them around.
4) Two more screws and nuts can hold the adapter plate to the sensor. I used #10-32 screws again BUT other sizes/threading would work. The catch though is that you may need to use washers or something to get a nice tight yet still removable fit.
Another option is to put the adapter plate ON TOP of the TPS sensor so you will have (plate -> sensor -> throttle body) instead of (sensor->plate->throttle body) like in my setup.
This will make the attachment of the TPS sensor to the adapter plate a LOT easier but you will only have 1 screw point usable on the throttle body (plus the support of the throttle plate shaft itself. I didn't like this idea.