To repair this, you can cut and insert a piece of 1/8 inch brass tube. You may need a tiny bit of JB Weld to secure it. This piece will need to extend a bit below the gasket surface...not too far, though. I did make this prettier before I finished. Please see image number one below.
And this important vacuum passage (the one for the power piston) can be improved by adding a brass tube. Please see image two below.
Rochester actually added tubes similar to this along with rubber o-rings in some of the BV and other variants to minimize problems they knew existed. I believe with a straightened air horn and float bowl you won’t need an o-ring, but I’m not against adding one. The trick is to get one slightly less thick than 1mm. No sense adding extra pressure here.
These are the problems I noted (the ones above the throttle body...which really are the ones which will cause your Rochester B or BC to not work correctly). Now please stay tuned for an explanation on how to straighten your warped castings...
~ Jon 1952 1/2 ton with 1959 235 | T5 with 3.07 rear end
