I AM A PJ34 GOD!!!!!!!!!!!!!!!!!!!!
Well, maybe not. But I did figure out the problem! FLOAT SETTING IS CRITICAL, not just important but critical. The float looked fine at first glance, but then I realized it had been set with the carb fully inverted, so that the spring loaded needle was depressed. What looked like 16mm from the gasket surface to the top (or bottom depending on how you look at it) of the float was really about 21-22mm, maybe more. This made my fuel level extremely low in the bowl. Basically sucking air. Of course with that small amount of fuel coming through the idle circuit, it was necessary to use the cable to pull open the slide to get fuel from the pilot circuit for idling (sound familar anyone?) or worse, crank the idle knob so far up that there wasn't any choke and anything larger than a 35 pilot would cause it to fall flat on it's face.
Right now it has baseline settings of 50 pilot, 160 main, DGH needle on slot #3, 1 1/2 turns on air screw, idle knob turned up about 1/4 of the way, idles good,
slack throttle cable, slide fully closed! As you can probably tell, I'm flippin ecstatic. I can't wait til tomorrow to go finish jetting. I have high hopes of good low end power with that much pilot. It has pretty good response just sitting in the garage. More tomorrow.....
I'm including a link to my fav jetting info site, which I just noticed says to do the steps in a specific order and just about opposite of the way i've been doing it (sorry to anyone I gave bad advice to). Most importantly, it says to set the float level FIRST. (seems so obvious now...) I'm sure i've seen this link in another thread but couldn't find it.
http://www.angelfire.com/pa5/cannondale/carb.html