Norm, I had a few idle moments this afternoon, and had a bit of a think about this.
1. maybe the regular engine oil you said you use in the mix is causing 'stickiness' of the needle in the seat - and this gets worse as the fuel evaporates. If the engine is shut off then the fuel tap turned, you have the fuel line full and the float bowl full as well - this could run down as the fuel evaporates and clog up around the needle.
I always shut the fuel off 20 seconds before putting them in the stop position. However, 2 months ago it was dark and all I did was stop my PT commando, take the fuel line off and drain the tank ((as per usual). Next week, it took 2 pulls to start instead of the 1 every other time - I have to put this down to leaving the float chamber full.
2. I was going to suggest drilling out the brass and putting in a vitron seat, but I see you tried that.
You have done so much good work with these LM's getting them to idle, to have throttle control and stop reliably, it would be a shame to have one of these other little things to stop such good work
Converse, I personally don't let mine completely run dry, but it clearly doesn't cause any problems if your Commando is any indication. What I don't like to see is when people turn the fuel tap off with the engine flat chat and then run it out of fuel. Backing it off to idle then running it out can't be that harmful. Regards Tyler