Thanks for the replies - and now that I'm on a proper computer, I can type!
The float bowl is leaking gas from the bowl seal area (where the o-ring is) I have a bunch of loose and a few mixed screws on the bowls because of the worn out threads...this is probably the issue. When I pulled off the bowl I held the float so the needle would be against the seat and I was unable to blow air through it...so it appears to be sealing well. I didn't have a leak issue on this bowl when I took it apart the other day so it's surely not the overflow tube just cracking all of the sudden...but I did remember that from a previous thread! I will adjust the float height just a wee bit, get some proper oversize screws for the bowl and that should do it.
I'm overly excited at how well the bike is running now - it pulls beautifully right off idle all the way to redline 9,000 rpm without missing a beat, also no hesitation at any rpm in any gear...just go go go! I'll have to strap my gopro camera on the tank and do a video...for all the grief I've gone through with pods, jetting, bowls and carb sync and general engine tuning it has finally put a smile on my face to see the bike wake up and perform!
I went to a local bike night the other day and had bunches of people checking the bike out - lots of compliments, it was cool!