Thanks Skull. Well this thread is all over the place so once I get serious into troubleshooting I will repost in engine.
The interesting thing (to me) is it seems to run great for a while and also when starting. So at first glance at least, seems to only come on after about 30mins of use. BUT - I need to repeat that pattern a few times and see.
I did just have the engine down to put in a new fuel pump and had the heads off and manifold/carb off and cleaned carb. So lots of potential screwups...