Well. I'm just an f'ing genius. Carb does not appear to have any vacuum leaks anymore, but really can't be too sure. Started up great as I said, till it overdumped. Now I've got a stuck side seal on the second rotor, which is the one with the hole in the header. Tried to just rev the hell out of it, but of course that didn't work! I'm wondering if it's carbon or some of my wonderful sealer!?! I'm going to pull the blown header off this evening(the new one should arrive tomorrow), and spray Seafoam Deep Penetrate in both plug hole and exhaust hole till I empty the can. Hopefully this will work. Any advise on manually manipulating the seal while the header's off, or any other advise would be greatly appreciated!!! Never smoked at all until the return line clogged.

 

You could try rotating the the e-shaft til the stuck seal shows through the exhaust port, then hose it down with some seafoam, let it sit a bit, then go at it with some pliers, or perhaps a tool that won't scratch or ding the seal itself.

 

Reving does nothing for stuck side seals, Seafoam is your best bet. Fwiw, side seals can't bee seen in any detail from the ports, even with a boroscope.