Had a chance to fire it with an absolutely positively proper and documented baseline this afternoon. When the temp was nearing 160* the idle was climbing toward 2K rpm with the pri/sec transfer slots exposed .023 and idle bypass valve at 1.5 turns out.
I said F it and started experimenting to see what it would take to get good off-idle throttle response. First move was reduce secondary butterfly opening 1/4 turn to lower the idle (Set at 5/8 out from closed) which dropped the idle to 1,600, another 1/4 turn dropped it to 1,250, this time I knew the butterflies were an 1/8 turn from closed.
I was checking response in between adjustments and it was still hollow with a stumble but improving. I reduced the primary butterflies a 1/8 turn and the idle went to 1,150, then another 1/8 to 1,050 and finally the hollowness and stumble was minimize. Next was 1/4 turn in on the idle bypass valve which had little effect on idle speed, another 1/4 turn moved the idle to 950 which is about optimum for this cam.
Next was idle mixture screws, keep in mind the transfer slot exposure indicated the butterflies were not equal dimensions from passenger to driver side on primary or secondary bores. The sweet spots ended up being 1.2 to 1.4 turns out and 10.75-11" of vacuum. Throttle response was finally close!
The test drive confirmed the carb was now in the ballpark, still has a very slight stumble but I can roll a 90* residential turn in 2nd gear and not have the motor fall on it's face which tells me the idle signal strength is finally close! I'm guessing it's within a 1/16 of a turn on the butterflies and idle mixture screws.
I also switched power valves from 6.5 hi-flow 2-port to 5.0 hi-flow 4 port and that appears to have created a slight hesitation transitioning into the secondaries that wasn't there before. I'll throw some 5.5's in and see what happens.
So much for the Holley tech telling me that the transfer slot spec on this carb was supposed to be .025". Only thing I can think of is he must have been giving specs for a 4150 without the idle bypass valve. I ended up with the the primary butterflies about one turn open which is about .010" transfer slot exposure and the secondaries are open a 1/16 of a turn so no slot exposure.
I'm guessing closing the primaries a little further and raising the idle with the idle bypass valve will strengthen the signal and get it in the sweet spot.
I know.........it would be way too easy to plug the car into a laptop and push buttons.
But I have a 60's muscle car not a Y2K tuner car.