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I have been having my own issues with fine tuning a new (to me) set of HIFs but here is what I've found. Please correct me where I'm wrong.
"Seems like they should sit flush, but they could not possibly sit flush if the Haynes diagram is correct"
I bent the tab on the adjusting mechanism inside the fuel bowl to eliminate this problem. I think a previous owner or mechanic "over" adjusted with the mixture screw and bent the tee shaped piece. I bent it back so I could get a range of adjustment with the mixture screw from flush with the carb bridge to well below it.
"Can anyone confirm that there is only one choke?"
Don't remember ever seeing a single choke on the dual SU set-up. Had a single choke on Strombergs as you stated.
"Hot start valve" is actually just a fuel bowl vent. You can pipe it to a charcoal canister or vent it to the atmosphere.
"Big nipple" also went to the charcoal canister to provide vacuum. You can plug it off or pipe it to the canister.
"Small nipple" is for vacuum to the distributor diaphram.
Don't know about the damper swap.
Good luck
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'60 544, '68 220S, '70 145S, '72 144E, '86 745T
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