Thanks to the responses to my problem. I think its fixed.

As I was taking the float bowl bits apart (for the umpteenth time), I noticed that the pin that holds the float to the float bowl lid had a dark film on it. I cleaned it up, as well as the holes that it fits into. I noticed that the pin and float moved easier on the hinge, but did not think that was the problem as it seemed to move fine before I cleaned the pin.

Took it out for a few test spins, and no overflow. Bone dry at idle and running. So I guess this thin layer of crud was enough to hang the hinge intermittently and the float bouyancy was not enough to overcome the slight resistence. Well that is my theory anyways - seems to work, but I'll keep my eye on it.

Thanks again all.

waggin.