The latest update in this little fiasco:
Tried the carb needle test, its definitely working to seal fuel in or out. If its the Chinese carb, its something more hidden, like an improperly drilled air passage. I've cleaned it, wheedled all the passages with a twist tie wire, float nice and level with the carb body, damned if I can see anything wrong with it. To recap, this is what I've done so far:
1. Cleaned gas Tank with Ammonia, let sit overnight. This did liberate a small amount of varnish like gunk, but nothing chunky. Let it dry for 48 hours and then hosed it out with WD-40, which seems to have pushed out the last bit of water that didn't evaporate. If it's an internal filter clog, I can't get to it. I tried blowing through the gas fill opening and didn't get air out of it anywhere but the outlet tube.
2. Aftemarket Carb Replacement
3. New gas cap
4. New Air cleraner housing with new primer
5. All new gaskets, carb to air cleaner, carb to intake manifold.
6. New fuel hose
7. Resistance test (apparently a wast of time) and cleaning of the coil, tested within spec, set magneto gap to .010". Kill switch wire looks good, obviously working.
8. Inspected and removed intake manifold, no cracks or obvious problems with the manifold gasket to cylinder head, looks likes it's never been removed. Having removed the intake manifold (gasket stayed on the head like it's glued on), I should probably replace it.
9. New Spark plug
10. WD-40 test for air leaks around carb while running negative, but I did NOT try spraying around the cylinder head to intake manifold gasket, which requires removing engine shroud while running. I think I'd rather just replace the gasket.
I have a useable mower here, I can get through the whole lawn without it stalling, but it usually requires 2-3 pulls to start, and begins surging after 5 mins. +/-.
From the suggestions posted, all I have left to try is a spark test (which I'll do as soon as I can get over to Harbor Freight to pick one up) and replacing the carb with OEM. I'm returning the Chinese Cheapo.
One question on the gas cap: Neither the OEM B&S cap or the aftermarket replacement has any kind of hole in it anyplace I can see. How does air get sucked into the tank through the cap if it has no openings?
BTW, does anybody know if the E-Replacement part carb is OEM, its around $38 vs. $50+ on the Briggs website. I realize thats the safest bet, but hate paying $20 more for literally the same carb just becuase B+S is cranking up the price.