yeah, i've tried everything from 2.5 to 4.0 turns with no success. I also tried covering the holes in the airbox, but got the same results, except then i also had a serious lag in the bottom end of the throttle. i think it just plain needs more fuel in the bottom end. I checked with Dale (Spec. Spares) and he confirms that if I've already removed the AI (which I have), that it's probably the pilot that's too small. he's sending me some 48's.
in the meanwhile, i plan to install the TBS needles i picked up yesterday, but doubt that will help much in the low end.
thanks everyone!
p.s. does anyone know if the pilots i can pick up at any HD shop will fit? they use basically the same CVK carb, right? it's gonna take at least a week to get them from Dale.

and, yeah, i have those allen screws for the carbs, but forgot to put them in when i did the job last time! ******...