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Have you tightened up those three bolts holding the throttle body onto the main carb body yet?
Remember?
The ones you access by holding this
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over your head?
You will probably notice an instant improvement in power, idle, and fuel consumption once those three bolts are tight again.
Once you solve your stock carburetor problems, you can get into the more esoteric issues of fuel/air mixtures and go ape sh*t on crazy fabrications for wild horsepower.

It's nice to dream; fix that car of yours!

Yep, I fixed it. Thanks phil. Should have told you I did. Sorry M8.
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As far as your list goes, its a good start and pretty much covers it. A little piece of advice I got along time ago from fabricator friend....cardboard, masking tape and foam board are a lot cheaper than aluminum and steel. Its easier to swallow a mistake with a cereal box and paper towel tube than a laser/plasma/water jet cut flange. Take your time and do it right the first time. Its cheaper and easier.
Have fun.
Hehe. Yeah I used to work at a machine shop and fabricate/make parts for odd stuff. Mostly steel and aluminum. I am well versed in measure 20 times cut once.
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Well , I have a bad news for you , you cant bypass water passages in Mk1 manifold. They are integral part of the cooling system and include thermostat housing among other things.
I had a feeling I would have to add an extra bung for the coolant line. May have to take a closer look at that manifold.
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That's the advantage of a forum, the exchange of information, knowledge and experience
I agree this forum has been a huge help in figuring out problems with my sprint. Without it I'd be stabbing blindly in the dark.
Again thanks for the information!
I hear that bike carbs have a problem with lateral G forces. So when turning they will get fuel starved. Is this true? And is there away around this by adjusting the floats?