j cAT:
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I would remove the carb and with a dremel tool smooth out those slightly damaged edges...this can effect the mixing of air to the fuel ..
the secondarys under normal operation do not fully open...about 3/4 ..the adjustment is a spring that gives the delay in the opening..if too light it can backfire stumble...
you should also have a vacuum controlled linkage locking the secondarys under certain conditions...
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I will use a dremel in the near future to carefully smooth them out. Do the secondary throttle plates only open about 3/4 of the way or did you mean the choke plates? The only reason I want to be sure is because I bought another used carb on ebay and it too has secondary throttle plates that extend completely vertical (although it's possible it is maladjusted too?)
I do have a vacuum break for the secondaries and it is adjusted correctly. Oh, and I will check to see if the engine vacuum is erratic too. Thanks for your help!
Blt2Lst:
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One very important thing to check on the q-jets is the throttle shaft for wear. With years of use, the shaft wears out the bore in the base plate of the carb causing a vaccum leak.
To check, hold the throttle shaft by where the cable attaches and try to wiggle the shaft, if the shaft moves where it goes thru the base plate, you have a worn base plate which will contribute to idle and driveability issues.
You can have bushings installed to correct this problem.
You should also have the TPS and mixture control solenoid checked while it is apart and replaced if needed.
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I have checked the play it has moving from side to side horizontally (the whole rod left to right, not turning) But for some reason never thought about possible gaps around the bore. I have already re-installed the carb back on the car and will check this next time I look at it.
I have checked the TPS and it seems to be almost set perfectly and the M/C solenoid is working correctly. Getting different secondary metering rods sounds like fun

even if it is not a huge WOT performance increase, I'll consider it in the future -- sounds inexpensive too. Thanks for your help!
Thanks Blue Bowtie for your detailed instructions and pictures! When I check the carb, and if I find this problem, I will use what you posted to fix it.
Another question... Does anyone know if these carbs have lead in them? They seem very heavy and soft as if they are made with lead. I have been handling mine a lot and taken it apart numerous times...
Thanks.