318 2bbl won't idle without choke

How are you measuring float level? You’ve said a few times that they are 1/4” and perfect, but maybe there is something procedural going on.
https://www.carburetor-parts.com/
Has a lot of useful information.
I turn the carb upside down and measure from the middle of the top of the float to the top of the carb body, as described in the FSM. The reason I'm almost positive it's not the float level is because when I take the air horn off after cranking, fuel is still coming in past the needle and the floats end up submerged after a bit