Norm, what about throwing a few in a bucket of 2 stroke mix for a month or so to get max swelling out of the way
I reckon a great deal of this issue is related to the swelling. Install, runs fine. Shut off engine then turn off the fuel tap - means the needle is at full height; the viton expands and catches in the seat (best case sticking, worst case damaging it).
I personally run them a little while after turning the tap off (but don't let them rev out at the end) and don't tend to have issues - but when I do I have a spate of them.
Max, I also find the old caps best, but they are progressively getting thinner on the ground. GA spares ones are useless, Victa genuine passable and Carbymasters are better, but still none are perfect.