LOL Coop, on the Klotz thing. I love the way it smells(the green label Benol) and got almost 80 hours out of a topend on my old YZ, but it's was a PITA to clean up.
On the rebuilds, did you re-torqued the jug, head bolts,and reed block mounting bolts after the break in heat cycles??
This is an often over looked and very important step in break in procedure, as the aluminum jug and head expand when heated up, and contract when they cool. I check/re-torque the bolts after each heat cycle and ride in intervals.
It also sounds like you might have forgotten to turn off the choke