I've rebuilt many (100's) of carbs. Removed everything... including welch plugs.
I'd run them for hours through the US cleaner, install a new kit, triple check everything.
Sometimes you get a carb that just will not function properly. I'd tare it back down... check everything again, still no luck.
I don't have an answer why, unless it's something internally worn on the carb. I run into that about 1 in 20 carbs.
I've used near 30 of the China Walbro copies now. They work fantastic and can usually be had for under $10 to your door!
For that money, I'd get one and see if it makes a difference.