Tell me more about the air leak. That doesn't sound right to have an intentional vacuum leak.
I have had to drill out the main jet to get rid of surging, but not 5 sizes.
Sounds like either there is still a vacuum leak, or at some point there was gas left in the carb and it clogged (even though it was new, it was probably test run, or someone returned it and carefully repacked everything), or the carb is defective.
Have you looked into an Ebay replacement carb?
Being a new engine, look for the unexpected, defects you would normally not see on a proven running engine.
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Today's Featured Article - Earthmaster Project Progress Just a little update on my Earthmaster......it's back from the dead! I pulled the head, and soaked the stuck valves with mystery oil overnight, re-installed the head, and bingo, the compression returned. But alas, my carb foiled me again, it would fire a second then flood out. After numerous dead ends for a replacement carb, I went to work fixing mine.I soldered new floats on the float arm, they came from an old motorcycle carb, replaced the packing on the throttle shaft with o-rings, cut new ga
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