We went out yesterday, did some figure 8s and the rear end noise is gone. The car is a symphony of weird noises though. We had to head back home when I noticed a clicking that correlated with wheel speed and stopped when I hit the brakes. There seems to be something in the passenger front doing it.
Update: yeah it was the outer brake pad.
I assume the pad was rattling. Is the car A-body or A-/E-body brakes (big bolt pattern)?
Also the idle speed jumped up about 500 RPM again at some point. I forgot to bring any tools so I stopped at a Dollar General for a screwdriver and slowed that down. It seems like an inverse fast idle - I might need to adjust/set that up so it is in effect while the choke is on and then set the idle so when it jumps up it's in the correct range (IOW where it is right now). I don't understand why the idle increases though - makes no sense to me. But I promise you the choke was wide open long before the idle stepped up. I haven't started it cold since then but expect it to barely idle without help since I took a quarter turn out of the adjuster screw.
You have to set the choke and fast idle with the carb ice cold, and the fast idle with the carb warm. Now, if that car only has the one idle screw, then the best thing I can tell you is to clean the cam and its surrounding area as good as possible, and maybe hit it with some silicone spray or something. If it's simply a cam on a single screw, that cam needs to move freely. It's been awhile since I messed with a Holley that had a choke, and the last time I did, I was removing the choke.
I noticed I raised the fuel level too much on both bowls too. I heard a bunch of detonation at one point, so I went ahead and filled it up with high test this time. Timing is at 15*, max 34, but it could still be coming in too quick.
Although I have a hard time believing it, 34° might be more than it wants. You could try dropping a degree or two and re-test. However, I'd suggest playing with the vacuum canister first to see what effect it has.
It's also possible that the newer carb has the high IFR, which causes the air-fuel ratio to fluctuate wildly while cruising. I've heard of guys swinging between 12.5:1-16:1 with the high IFR. Of course, fixing that requires taking the bowls and blocks off and drilling, but it's well worth it. I'm assuming you've adjusted the idle mixture screws to the max vacuum reading at hot idle. If you haven't, get after it.
Taking a chance on that transmission being good wasn't the best choice because it seems like I've got a bad synchro for the 2nd gear shift. I'll adjust the shifter but I don't think it's related because it goes in gear, it just makes a racket about every 3 shifts. I couldn't see anything wrong with them while it was out of the car but it's not like I'm Dan Brewer and know what I'm looking at either.
When checking synchronizer rings (the synchro itself is rarely the issue), there are two things you need to do, one of which absolutely requires the transmission to be apart. The first thing is to feel the angle on the top of the teeth. If they're sharp, replace them. New ones are rounded on that peak. Really, if any edge other than one along the flat side feels sharp, I toss it and install new. That test you can half-ass do with the side cover off. The other test is to loop your index fingers inside the synchro ring, and pull hard. Now rotate it and try again. If there's a crack, you'll find it. Obviously, the rings must be out of the transmission for this. Cracked synchro rings are more common on the older, square-notch rings than it is on the '70-up style tapered slots.
I know I mentioned it previously, but GL4 oil only. Parts-store GL5 is not backward compatible and will chemically destroy the synchronizer rings, period. The only two remaining oils of which I'm aware are the Penngrade GL4 and Redline MT90. The latter is synthetic and aboot thrice the price of the Penngrade stuff. One can also use Dex/Merc automatic transmission fluid, since that's what A833ODs specified. For heavy-duty running, though, I prefer the 80W-90. The A833OD for my '68 will get the ATF, because I expect to drive that car year-round. Experience has taught me that trying to shift an 833 with 80W-90 at -10°F is like trying to move a paint stick through chilled molasses.
I revisited the the temp sending unit and it seems to be working (117 @ 210*, 155@ 190*) so I guess it's something to do with the dash. Remember I tested the fuel sender too, so the wiring and the senders both seem to be working as they should. Weird. I could really use a working fuel gauge.
I found my NAPA/Echlin .pdf with sender specs (thank God; I forgot about it until now). Per their sheet, it should be 24.7Ω @ 220°F and 152.2Ω @ 100°F. Since their sheet is jut a stolen copy of Standard Motor Products despite not selling that brand, it should be the same specs for the TS17.
Finally, I'm still not convinced the rockers aren't making a racket. It sounds more like a high speed clicking than a valve tapping.
Try and narrow it down. Pull the belts and start the engine to remove the accessories and fan blade from the equation. Pull the dipstick out; it could be contacting the crank. Turn the lights off and run it whilst eyeballing the engine. Mist it with water from a spray bottle. You'd be surprised how loud leaking spark can be. Make sure nothing mounted to the engine/trans/bellhousing is touching something mounted to the body. I realize it's unlikely, but don't rule anything out.
I watched an interesting
video regarding lifter face finish. That channel has done a lot of research into flat-tappet cam failures and really hasn't found the answer, however just looking at the lifter faces at the beginning, I don't know that I'd trust 'em. They just look like they're sloppily machined. Dude does have a Rockwell tester and says he's not yet found hardness issues in failed cams and lifters, and in one video he even checks a ~40-year-old factory cam as a reference. It's no harder than a current aftermarket piece. I haven't watched all his videos, but he's clearly not solved it yet.
One thing I wonder about is valvesprings. I don't think yours are anything ridiculous, but I wonder how many cam failures are related to attempting a cam break-in on too much spring. On doubles, you're supposed to break in the cam using only the outer spring. Are some of today's stiffer springs exerting too much pressure during break in? I don't know the answer but I'm definitely curious.