Hi Jaffa, i've been following the thread and you've got the pros on your team on this one. I will add/re-confirm one thing though; The 2 gaskets and the spacer play a huge part in that machine running right. The first gasket, which goes on the engine side, and the insulator are pretty straight forward. The final gasket is the one that will definitely give you grief if not put on in the right position. The little hole must be on top and off to the left a little when installed, exactly as set out in Roebucks pictures. I noticed in your photos you have it on wrong. Once installed correctly the bottom of all 3 gaskets will line up flat along the bottom edge.
Bassic deductive reasoning tells us it was running ok prior to the carby clean. So either the gaskets are all jumbled up and incorrectly placed or the carby is stuffed, which i doubt as it runs sweet when the air filter cover is removed.