I knew the starter was different. I was specifically going to the mini starter because I understood it to be a better design: using less current, spinning faster, and being a longer-lasting piece. As I have mentioned several times, I don't really have an option of having the car in a non-operable, non-movable state for very long, so taking the starter out, having it rebuilt, and having the car sit without being able to move it is just not really an option. So while I was unaware that the starter could be rebuilt with higher output, I would have made the same decision. Plus, when I eventually move to dual exhaust, it will be easier to route past the smaller starter.
Regarding the alternator, the same thing applies: I have a very limited time to get the work done. If the issue is re-routing a ground wire, I'm fine with that. I just want to get confirmation that my suspicions were correct about it.
The hot start issue is unlikely to be from a buildup over time, since the carb is new, and the problem appeared early on.
Your description about the gas vaporizing and puddling makes sense. The pattern is such that if it's hot, and I just stopped it, it starts right up. It's only when it's had a chance to have the heat soak in that I have problems. I had imagined that the fuel was vaporizing out of the float bowls, and I was waiting for new gas to be pumped in, but the puddling and rich condition makes as much sense.
I'll check out the issue of the cross-over, but I don't understand how that would cause it to increase the heat. Can you explain?
This is as much an answer to your questions as it is to DetMatt's response below. The passage in the intake manifold is intended to run hot exhaust gas through the intake to speed up engine warmup. When the choke is improperly set, especially in the winter time, there's a lot of unburned gasoline that's part of the exhaust gas flowing through the intake and it settles out and slowly plugs the crossover passage. Sort of like hardening of the arteries. So while the passage is now getting more and more restricted, it's still flowing some exhaust gas and it gets all of that carbon deposits really heated up. Even if the carbon eventually blocks the passage completely, you're still going to have exhaust gas heating everything up and the carbon just acts like a heat soak, that very, very slowly gives up the heat it's accumulated. So when you've been driving for any length of time and everything is up to temperature, the engine can deal with the passage being blocked off. It can also deal with a restart from hot in a very brief period of time. But give all that heat time to boil off the gas in the carb, and you've got what you're dealing with now. All that carbon has gotten really hot, gotten the intake really hot and the carbon gives up its heat much more slowly than the cast iron would cool off, if the passage was open. Also, the lead in older gasolines helps with the plugging up. Everything else being equal, the unleaded gas won't create this mess as quickly. I know, I know, everybody hates ethanol and so do I. But your car was meant to run on premium or close to it, and modern premium gasoline has far less ethanol in it than the current "regular" grades, so once you've got the passage cleaned out, it'll stay cleaned out longer.
What DetMatt is talking about is having a manifold gasket that blocks off the exhaust passage entirely. If you lived somewhere that's warm all the time and a "cold" night goes down into the 65°F area, the car can deal with starting up in that, because for the engine that's not really "cold". But if you live somewhere where the choke stat is going to actually try and close the choke because of low temps, then you're going to have a whole new problem of the car being a ***** to start and keep running without any carb heat from that crossover passage. In cases like this, the engine will eventually warm up (it'll take a whole lot longer and you'll burn a whole lot more gas until it does) and then it will be getting the carb heat from convection coming straight up from the block.
If you're running the stock exhaust manifolds, it's crucial that the heat riser valve in the exhaust manifold is working properly. If you can turn it by hand, it's working OK. If it's stiff, you need to soak it in penetrating oil (NOT when the engine is HOT!!!!!!!!!) and work it back and forth. Also use a small hammer and tap the shaft back and forth gently to free it up. Chrysler used to sell a really, really good heat riser solvent, but the stuff made the EPA go nuts, and Chrysler had to discontinue it. I still have a little bit and only use it when really necessary. If you have a "Krown" oil spray dealer in your area, their penetrating oil works really well also.