Barry,
The main problem is with the recessed balls. Bending a punch will remove the side balls near the load jets without too much trouble. But the main problem with plugged passages I have run into are the idle passages involving the balls which are deeper in the casting.I'm afraid Dave is correct about use of a wire welder, and that often takes repeated tries. I have tried many approaches to remove the ball bearings, the last being another shot with a coated carbide ball end mill recommended by Niagra Tool. The balls are around Rockwell C60 hard, and even carbide end mills dull working on that hardness. I tried heating the balls first to soften them, and that worked on the top surface but they contact too much of the surface to get them hot enough to have much effect. And the end mill dulls after the heated top surface is removed. There is another, time consuming approach I used involving drilling down to the ball, then using a drill bit ground concave on the end to fit around the ball to remove more of the metal around the ball, then drilling a hole at a right angle to the ball and using a punch with the tip ground at 45 deg to pop the ball out. A lot of trouble to go through, and if the drill bit drilling the right angle hole wanders before it gets to the ball (as does happen) life gets even tougher. And then a new ball does not necessarily stick as there is not enough metal left around the ball. So, locate a person good with a wire welder (I use .024 wire and a 110 Miller gas feed). I drill out the holes leading to the deep balls in the manifold end of the carb to 1/4" to improve access to the balls. When everything is clean I replace the balls, and the manifold gasket covers the enlarged holes.
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