Thanks for the info (Dr Al + Dan). If that is the problem, a simple spacer between the impulse line and the case should cure it. Like I stated previously, the carb issue on these saws was driving me crazy, and I was very hopeful someone would discover the problem.
The AM kits take about 3X longer to assemble than OEM due to poor fit + finish. However, OEM 044/440s have all but vanished from around here, and being semi retired I view these as a "puzzle challenge". As such, I really appreciate that these low cost kits are out there, and I have acquired 3 more to turn into Hybrids (I will use OEM 460 pistons and the HS Supply Door Buster jugs). The one I did that way seems to run pretty well, noticeably better than the BB ones I did, and the HLS jugs seem to only need mild mods.
If I were trying to make a living based on my time, I would not touch an AM saw. Fortunately, this is just a hobby for me.