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I read your post and I understand and agree with it, There are a lot of variables at play.
Here are more realistic numbers from a 1961 225 engine, removed from a new Dodge Lancer, put through a 50-hour break-in, meticulously checked and set to factory specs, and put through well-documented tests in March of 1961, NOT by (or on behalf of) Chrysler:
Gross output (air cleaner removed)
Maximum BHP 126.5 @ 3800 rpm
Maximum Brake Torque 210.7 lb·ft @ 1600 rpm
Maximum output (just shy of detonation)
Maximum BHP 115.9 @ 3800 rpm
Maximum Brake Torque 196.9 lb·ft @ 1400 rpm
As-Installed Output
Maximum BHP: 104.5 @ 3800 rpm
Maximum Brake Torque: 189.4 lb·ft @ 1400 rpm
These numbers are notable for a bunch of reasons: they don't conveniently end in nice, tidy, round, advertising-friendly 0s and 5s like Chrysler's 145 (hp) and 215 (torque) figures. The gross BHP figure falls well shy of the published claim. It does, however, match up very well with the "127" rating Chrysler published for the industrial 225 configured and equipped just about identically to the passenger car engine in all the ways that mattered to output. That looks a lot like it was wisely decided that the only real purpose of a horsepower number on a passenger car is to sell the car, while people specifying industrial engines have a genuine need to know what they're actually getting. Also, the as-installed figure and the gross-output figure are clustered closer than the two numbers you wanted to use.
Elsewhere in the same report is a graph of fan horsepower, considering the 4-blade solid fan as installed in a 1961 Dodge Lancer. The figure rises exponentially with engine speed and peaks at all of 4.4 whole, entire horsepower at 4400 rpm in still air. That's a speed seldom seen by a 225 in real usage; consider a car with 205/70R14 tires and a 3.23 rear axle ratio, with a non-overdrive transmission. At 60 mph, that engine is spinning about 2600 rpm. At that speed, the 4-blade solid fan was eating up
one horsepower in still air. Change the axle ratio to 2.76 and we're at 2200 rpm, where the fan's hogging up six-tenths of a horsepower.
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Another variable in the eary 70's was gasoline changing from leaded to unleaded. I don't how old you are but I remember how bad the early unleaded gas was.
With the exception of one or two companies who offered a no-lead gasoline in certain parts of the US starting in the '60s, unleaded gasoline became generally available in mid-1974. There was nothing the matter with the early unleaded gas -- it was not "bad" -- it was just only available with regular-grade octane levels (91 RON, that is 87 AKI...same as today's regular gas at sea level). It was perceived as "bad" because it didn't run well in high-compression engines that called for higher octane fuel, nor in engines that originally ran fine on regular but had been accumulating lead sludge in their combustion chambers and so now required higher octane...and there were many of both kinds of engine on the road when unleaded came in for '74.
And none of this is relevant to the question at hand for a couple of reasons: engine performance rating tests were not done on gasoline obtained by driving down to the local gas station, they were done on fuel of standardized characteristics. And there was plenty of high-test leaded gasoline available at any/every gas station well into the 1970s.
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Bottom line is that the largest drop in hp between gross hp and net hp is the addition of accessories added to the engine.
No, the biggest drop in HP between gross and net published figures was due to the rising cost of auto insurance and the increasing traction of auto safety regulators. In the '60s, bigger numbers did a better job of selling cars. In the '70s, smaller numbers did a better job. Surely you didn't think the industry devised the new net system and switched to it out of the goodness of their pure and noble hearts, so they could sleep better at night 'cause the consumer was getting a more realistic (and equally meaningless) number!
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The biggest power grabber is the fixed blade fan.
No, sir, it is not. Bigger by a large margin is the exhaust system.
(Preemptively: Not from me, you can't. It took me most of two decades' effort to get hold of it, and the terms I got it under let me quote from it, but not republish it. It is not mine to share.)
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