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I rebuilt my TO-20 carb last Winter. After the rebuild, the float needle no longer provided 100% fuel shut-off. If I don't close the fuel bowl within ~30 minutes of turning off the engine, the carb floods. I've pulled my carb twice to re-check the float gap, even installed another rebuild kit needle and seat... same problem. Sounds like you may be having the same problem. Because of this new development, I also discovered my old fuel bowl was leaking by. Had to buy 2 new fuel bowls because the 1st new bowl leaked-by also. Got a good one now, finally. Never had this problem before. The old needle was all metal, the new needle has a rubber tip, don't know if that is the reason. The float and mixture settings in my rebuild kit, and my manual were different. I used the manual settings - idle mix (small screw) was 7/8 turn open, the power adjust (big screw) was 1 1/4 open. When I got things running, I found those settings were perfect. This will sound stupid, but when I reassembled my carb, I had the choke spring and flapper bass-ackwards so the choke was normally closed, instead of normally open. I realized my error when I went to re-install the carb.... a minor set back that I had to correct.
Check that float gap again, make sure your fuel bowl shut-off works, then use it. Try the mixture settings above. Hopefully some of this will help. Sorry this is so long... I just went through exactly the same thing ! Good luck !
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