Jetting help needed

I could be wrong, but I am sure that there is a 44 available. I may have one around here somewhere. I will look and see. If I do, you can have it.

Needles make a big difference, they may look the same but are not if you check them from top to bottom and check the tapper,
I've had the best luck with the 88 year sporty needle, or the stock needle in the middle grove.

If it was me I would start at the beginning, make sure the boots on both cylinders to intake are not sucking air, I would get a diagram of the carb and take it apart one more time, and make sure it is assembled correctly, and with all the parts in the right places, I'd put the 45 pilot and a 170 or 180 main, I'd set the needle screw is 2- 2.5 turns out. I would put a little bit of grease on the inside of the carb to manifold boot and slide the carb in as I twisted it into the location needed to keep it in the correct position. Make sure the carb is not sucking any air outside of the filter.
If you do not have any air leaks, your problem is some place else, these carbs are pretty much bullet proof and very simple to work on. My guess is you keeping making the same mistake over and over. Take your time and be patient as you do it one last time. If you need a diagram for the carb just ask someone.

Maybe it is time to take it into a pro wrench? From what it sounds you have gone through that carb more than once to no avail. However the last thing to try is to shim the needle. If that doesn't work, then bring it in. No shame in that.

WTF are you at WOT right off of idle for?

Guesstimate, at what throttle position? Right off of idle, .025 throttle, .500 throttle position?

Read through the posts looking for something missing, really suprised by lack of success with the carb kit if installed correctly, and it sounds like you have gone through it from top to bottom.
What is the sparkplug condition in all of this? I see no mention of checking them for fouling or checking their gap, unless I missed something. With all the other success in all the other carbs by all the other users, I am still puzzled by your not having the situation repaired with this if the problem is in fact carb based.
Either way, good luck with the bike.

My guess is that he has a screwed up head gasket. It is still possible that even though he did the propane testing, that one, or both is screws up. I had that happen to me right before I redid the top end on my Sportster. It was backfiring and couldn't get it right. We didn't discover the bad head gasket until we pulled the top end.

You won't. If you have gone that far it isn't much further at all to pull the head. But it is your bike. Good luck.

Not always no. It didn't on my Sportster. Like I said, I didn't find it till we pulled the head.

Would it show up during a compression test?

Hard to say for sure. If you knew what the compression was on each cylinder prior I would think that you have a good shot at it. But there is an acceptable difference allowable between cylinders so one may check it, be within the allowable range and still think that the the head gasket is good.

It's drawing in air from somewhere.

Lot of Guessing going on here. Maybe take it to a mechanic that knows what to do and have it fixed.
Problem solved.

True, but if everyone on this forum "took it to a mechanic" all the time, wouldn't be much of an interesting forum, just a whole bunch of posts of pics of receipts.

And you wouldn't have so many bikes with something wrong with them.

The 1st thing you do is run a compression test. Then a spark test.
Then you look at the Fuel, How old is it.
Is the screen in the tank got anything in it.
Does it have water or trasn in it.
Then you look at the hoses. Has the ethanol eatten the hose up and particles from it has gotten in the carb.
And if you took the carb off. Did you damage the needle and seat.
Did you use a torch tip cleaner and clean the ortiface holes out.
Did you set the float adjustment right.
Did you refer to the manual for the air and fuel screw.

If the carb getting gas correctly to it.

It ain't it might be this. Or the head gasket might be the problem.
Or the back tire might be low.

A lot of people Bad mouth Harleys because parts fall off. And they always have to be worked on.
Problem is a lot of people want to be Harley mechanics. They want to work on them all the time.
You don't have to work on these bikes all the time.
You refer to the manual and do what it says. Then you can ride the bike and enjoy it
And people ain't seeing it broke down, or seeing the problems with it.

I've ridden Carbed bikes most of my life before I went to fuel injection.
Never had all the problems of it is spittin and poppin a lot.
I kept good fuel in it. Kept the hoses replaced , new clamps on it.
Kept the screen in the fuel tank Petcock area cleaned and checked.

I rode the bike everyday to work, and rode it on the weekends. I wasn't working on it all the time.
And having problems.
One of my bikes had a linkert carb on it.