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Bill, I think you're on the right track. Popping out the carb is probably a timing problem of some sort. An intake valve is closing too late, or a spark plug is firing too early. If it only does it occassionally and randomly, it could be a wobble in the distributor shaft, short in the primary side, arc in the distributor cap, etc. If you set the valves cold, try for around .022 cold (which should be loose enough to answer the question about an intake valve staying open) then recheck when warm to see if the expanded metal has taken up the slack, or expanded less than expected - and you might find some in either direction. After you've found TDC compression for #1, just follow the firing order - think it's 1-3-4-2 for an M - and turn the crank a half turn, or 180 degrees for each set of valves in sequence of the firing order to be certain you're on the backside of the cam for each valve you adjust. Good luck in solving the problem.
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