Re: mercarb needle problems
I dont know what kind of carb you have, but on mine (rochester 2bbl) you have to take the accel pump linkage off in order to get the top part of the carb off. Sure, you could do it without removing the whole carb if that is really easier. For me its easier to take the whole carb off.
My carb rebuild kit came with two different shaped spring clips to hold the float needle to the float, cuz the kit works for multiple carbs. I wonder if you might have the same situation and chose the wrong clip? Also check that the clip is properly connected to the float tab. On mine it goes through a little hole near the float tab. If you were to mount it 180 degrees around it would kinda still work, but it wouldn't be secure.
And re-check the float measurement that limits how low the float can go in the bowl. re-check the instructions to ensure that you are setting the measurement for your particular variation of carb and measuring between the proper two points. That just seems like the most likely culprit.
Good Luck