So, against the sound advice I've received here on this forum...I decide to just slap it back together and roll with it for now. LOL. Last weekend I torqued all the rocker arms back up, installed the new Eddy Intake and rebuilt 4 bbl carb. I re-installed the freshly rebuilt C4 transmission, and swapped the old manifolds for the new Hooker headers. The summit exhaust gave me some trouble, partially because the driver side header comes out at a steeper angle than the passenger side. I had to do some persuading to get that side to straighten up...and I'm not super happy with the results. At the end of the day, I was able to get it hung back to the mufflers so at least it sounds OK. I can now get it to a muffler shop in the future and have them make it right...but it will work for now. I would really just like to get 6-12 months more out of this engine and rebuild either a roller 302 or a 351C on the side while the car is still a driver. If it breaks before then I'll just yank it and deal with it.
After putting it back together, I was able to get it started but it was obvious that I had carb/timing/vacuum/etc issues. The previous timing mark (yellow mark on the balancer) was around 6-7* BTDC, so I silver sharpied it and set it to that initially. If I punched the gas in gear it would just die, and I couldn't get it to idle properly,and it seemed to be surging. I bought a new timing light with tach and a vacuum gauge kit this week. Today I moved the dist. advance vacuum hose to the full manifold port, changed where the accelerator pump bar was connected on the carb, and bumped my timing closer to the 10-12* mark. What a difference! She is idling much better (although still high around 980-1000rpm) and when I punch the gas in gear, my tire spins!
This is huge difference from before the intake/exhaust swap.
Unfortunately, after a quick run around the block, I was stopped, put it in reverse, and a horrible rattle started. It happens any time I'm stopped but in gear. No issues in neutral or park. Once the wife got home I was able to look underneath and at the engine mounts. I think I just need to adjust and tighten down the exhaust hangers because the passenger side is beating against the under body.
Pictures coming soon, for now I will leave you with just one. The former owner found some pictures of the car from years ago after it was rear ended. It wasn't driven much after this accident, even after it was fixed. I am guessing the transmission failed soon after the car was fixed up and then it sat for 15 years. I wonder if this accident actually caused the rocker arm problem, could that be the case???