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Specifically what spring pressure are you planing on running? Lift/duration aside it is the lobe design that will dictate the springressure/longevity. I would run and Isky 9905 os something close to that.
If you push the clutch pedal in and it makes horrible noises the clutch disc is most likey installed backwards. If that isn't the culprit the pressure plate might have a problem as mentioned.
I would just go to Dr Diff and be dome with it. As Doug said, unless you can do the fab yourself all of the running around and parts chasing won't be worth it. If you are going to beat on it go with a s-trac locker over a traditional power-lok.
I have 3 sets of 440 source heads and none of them would work correctly with a 4.375 bore head gasket. Make sure you check the fire ring agaibst the chamber.
The important aspect of head gasket bore size selection tyoically osn't the block bore size but the cylinder head chamber. As a for instance 440 source stealth heads require a 4.410" minimum bore head gasket in my experience.
The emulsion circuit emulsifies liquid fuel with air coming from the bleeds.
In my experience moving the IFR to below fuel level smooths out the idle and low speed AFR readings and also gives better control of the idle circuit in some applications. I say "some" because I have had a few engines...
I can steer you to the pertinent info online if the links are still good. There isn't too much theory to my emulsion tuning. I put a 750 holley metering block on my 1050 annular and it had good manners I copied the emulsion package and relocated the idle feed restrictor to the lower hole like...
Three things I always have to correct in the shiny carbs:
1) Restrict emulsion passages
2) Move Idle Feed Restrictor to lower hole (below fuel level)
3) Transfer slot restrictors (due to mile long t-slots in the baseplates.
That said, if you are happy with your carb don't think twice about...
Usually the old school dichromate Holley 750 VS (3310) or DP (4779) are good places to start for a streeter. If it has a big cam, headers etc 850 (4781). For the most part any of the shiny hp carbs qill require transfer slot restrictors, emulsion jet changes and air bleed tuning on top of the...