Tony,
A couple of thoughts. I remember that I had a bad problem with perculation, and my solution the first time was to install a phenolic spacer (I used a 1", but there are 1/2" ones). The phenolic, as you may know, is a lamination of paper, plastic, or some other isolating materials with a bond agent. It acts as an insulator of heat on these types of situations.
The second time I had the problem (quite recent indeed), I found the non-stick gasket with a cut lenght-wise on some areas of the gasket (probably from overtightening). I had check floats and needles and evrything else. Anyway, I replaced the gasket and it cured the problem.
Give it a shot, if all else fails.
p.s. If you feel alot of heat rising from the engine (like while under a tree shadow), and you trust that your cooling system is OK, then check the timing. Settings close to TDC will yield more heat (from the exhaust manifold) than settings away from TDC (obviously before TDC).