Update: I was able to get the needle aligned in the grove on the barrel last night but still after turning the needle all the way in, doesn't give me enough gap to keep my truck from dying during breaking. Soooo....after almost throwing it through the window I decided to drop by the LHS after work and let them have a peek. After telling them the problem they looked at me like I was an idiot...he says. "Turn the needle in so you get more gap dude". I said: "No kidding man, but it won't turn in anymore and it's only a .3-.4 mm gap or so showing..and that's not enough". So I give it to him and he takes the needle out, the barrel and the spring. Puts it back together, tightens the screw and gets almost NO gap at all! Yup, hes perplexed and flustered now and I DONT feel like such an idiot. So we decided to remove the needle spring and that gives it just a hair more of a turn in and MAYBE a .5 mm gap....I just put the truck back together but haven't tried it yet. He and his business partner are just guessing that maybe its a manufacture defect in the carb or needle??? Anyhow, I'll fire it up tomorrow and see how it goes..if it doesn't work, guess I'll be buying a new carb!