Repairing cast aluminum

I just removed the handlebar throttle housing on my '83 GPz550. I'd noticed that it was cracked before (see first photo), but the repair job is, how to put this politely, less than satisfactory. Seems that filling the housing with some sort of filler, bondo perhaps, was the best the guy could do (see second photo).

So, I'd like to do it properly. The housing appears to be cast aluminum (where the paint has chipped off it has exposed a dull grey material, can someone confirm that this is what these parts are made of, or are they some sort of high density plastic?) and I've seen online that such items can be "easily" repaired with an aluminum brazing rod and a blowtorch. As it's not a high stress part, would this technique work well?

Also, what is supposed to go in space currently filled in? Some sort of metal bracket to hold the handlebar, or just empty?

Thanks!

that repair is the dreaded JB weld but i would just replace it there should be a lot of them out there semi cheap

it could be tig welded if you have a friend with a welder

Not sure if it's cast aluminum or not. A lot of the cast alloy parts on these bikes are zinc. In any case, I like btchalice's idea. Put a want add in the for sale section. There are a few gpz owners here. Or start searching ebay.

Yeah, been trying to chip out the JB weld ... it's nasty stuff! Any easy-ish ways to get rid of it? solvent perhaps?

Thinking of replacing the assembly, couple of international (UK and Oz) sellers on ebay for ~$40 ... OEM replacement from Kawasaki is only ~$80. Going to post in the wanted section of the forum

Thanks!

Just replace it. Here's 1 used and 1 NOS:

cgi.ebay.com/ebaymotors/1984-KZ-550-H-GP...fPartsQ5fAccessories

cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll...3D719566768936504537

Wow, nice I found one for $25 from an '89.
Contacted the used one's seller to see what the condition is

Maybe off topic, but what does the "nos" mean? Clearly not nitrous oxide NOS

New Old Stock = NOS.

Archiddeon wrote: Wow, nice I found one for $25 from an '89.Contacted the used one's seller to see what the condition is

Maybe off topic, but what does the "nos" mean? Clearly not nitrous oxide NOS

NOS = New Old Stock

But now I'm confused. I thought you were looking for the throttle control for a '83 GPz550. That is part number 46091-1207. That part was used on the following bikes:

Model (5):
KZ550-H1 (GPz) (1982)
KZ550-H2 (GPz) (1983)
ZX550-A1 (GPz) (1984)
ZX550-A2 (GPz) (1985)
ZX550-A3 (GPz) (1986)

It wasn't used on an '89 anything. Are you modifying the bike just because of a cracked housing? Why pay $25 for the wrong part when you can get the correct part for $10?

I'm not planning on modifying it, and have given up on the $25 '89 one in favour of the $10 If the '89 was the only one I could find, it could probably have been made to work, though