Dave,
I did use a wire bristle to poke out the two idle ports. I am not getting fuel around the choke.
I just lapped the top of a 5 bolt carb I have and the fit is really good compared to the one on my engine right now so I am going to see if I pull the gasket off the 4 bolt one (it is a 5 bolt gasket) and put it on and see what happens. I think you are onto something with the air getting in between the halves.
I'll order a rebuild kit Monday no matter what but would like to see her start at least once.
I did double check the wire order with someone looking over my shoulder and that is correct.
For the timing I set to top dead center using a pencil to see the valve closing then turning until the roll pin was vertical. I then used static timing light to adjust the distributor. Basically I followed Don's video here:
https://www.youtube.com/watch?v=2ysFGcm8oNo
Thanks,
Brant