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niles,
Interesting read. I to am using a O2 sensor and volt meter to sort out my carbs. I'm curious as to how stable your mv readings are while driving. Mine go +/- 200mv and it is very difficult to estimate an average. As for the increase in mv when going to the 4.0 power valve, I have no personal experience, but have read that some power valves do not open anywhere near their rated vacuum. I suspect yours may be opening significantly higher than 4.0. I would either check it or try a new one.
Good luck and keep us posted, Steve
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