Got a few things accomplished:
Carb is rebuilt, but what a pain in the ass! I removed it Saturday morning and spent most of the day attempting to get it put back together. The only real problem was getting the primary metering rods into the primary jets, the spring makes it a royal pain and you can't see anything. After many attempts, and breaks to reduce frustration levels, my buddy came over and gave me a hand. Turns out it is easier if you have 3-4 hands. Once that part was in, it was a cake walk to get it put back together. I of course swapped the electric choke into place, but I assembled the secondary choke pull-off wrong, so I need to make a quick adjustment. It will be done later today. The plus is the car now starts/runs directly off the carb without requiring a splash of fuel. In fact it starts with little to no pumping of the gas, not even the 'normal' one to two pumps.
Replaced the fusible link running to the alternator, and confirmed that the alternator is working now. However, I found that the post on the back of the alternator was loose, so I need to pull it and tighten that down. I also found out it is a 94 amp diesel alternator, not the stock 85 amp that would have come with the car. Output is 14.4 volts at idle, so I am in good shape once that post is tightened down.
I installed the little spring wire that connects to the horn button, but found out that the horn itself is bad. I can hear the relay click, and I tested at the horn and I get power there, but no horn sound. I will grab a new horn when I get a chance and get it installed.
I grabbed a set of rubber valve cover gaskets, but haven't installed them yet. I have a set of Edelbrock aluminum valve covers, but I need to get a proper PCV valve grommet before I can use them. I also need to knock the baffle out of one so it can be used to fill the engine with oil. I have a K&N breather to use as an oil cap/vent, but haven't been able to find a grommet that will work. Just need to do a bit of research to find the right one. I will also be reversing the PCV valve side to the passenger side valve cover because of the routing of the heater hoses which makes it impossible to have a breather or oil cap on the back of the passenger valve cover.
Brass plugs are installed in the holes left from removing the AIR system. The car sounds much better without massive exhaust leaks from those manifolds.
Worked with my buddy to locate the vacuum advance distributor, and I will get it installed this week. Hopefully the ignition module is good on it, but I am sure I can figure something out if not. At least I know the engine runs now, so I can easily find the issue after swapping this out.
While we were looking for the distributor, we found an old cast iron water neck that only has one opening for temp stuff. It already has a plug installed where the opening is, which helps me not need to buy too many more plugs. I will install it with a new gasket and replace the t-stat with a new 160* unit.
I am waiting on the little follower that goes in the column to push the high beam selector rod, it was missing when I got the car. Once I get that, I can tear the column down and install it, as well as fix the sticky lock cylinder. Right now I need to manually turn the key back to run from start because it sticks.
So, a few things solved, and a few more issues found, but it is still forward moving progress since each step gets easier to solve.
I will post up a pic of the old carb later today, it was much worse than I had thought, the float was rusted and the interior of the carb was badly corroded.