I work on a ton of these Briggs flat heads and love fixing them up. So easy to get them going (usually). Couple of things for future reference.
1) Never rebuild these carbs. Rebuild kit is like $12, while a new carb is barely over $20. My time is worth more than $8, and a rebuilt carb doesn't work right 50% of the time. Just replace them for a much smaller headache. I've used a bunch of OEM carbs as well as the Chinese Oregon ones and they all run the same.
2) I personally only use Champion RJ19LM in these. Made in USA and good quality. Have had bad luck with other brands for some reason.
3) Gap at 0.020 if you think your coil is getting weak or if unsure you have spark. Run the gap at 0.030 for a good running engine, but knock it down to .020 for coil diagnostic or to limp along a dying coil.
4) I'm almost positive that your problem is a clogged up carburetor. It is really hard to clean behind the welch plugs. I'd put a new carb on it and chock it up as a lesson learned. Should start right up and run perfect with a new carb.
5) Replace the fuel line at the same time. I've seen them get spongy inside and slow fuel down.
1. Easy to work on... yes, that was my experience also, until I met this one!
2. Where do you get your parts? The Carb overhaul kit cost me $16 and the best price I saw on the Internet for a new carb was $35. We have only one store in town that sell these parts and they have bankers hours. I have never heard of Chinese Oregon. Where do you buy these?
3. I started with a brand new Champion RJ19LM spark plug. I tried three different brand new plugs, (2 Champion, 1 Briggs), and a used "known good" Briggs plug. I finally got it running with a new Briggs plug gapped at .030". I will try your idea of the .020" gap in the future.
4. I know I don't have any clogged ports. I was able to blow compressed air through
every port after cleaning the carb - confirming the ports are clear. The carb has only one welch plug, which I removed and was able to clean the port (or orifice) with a drill bit matching the diameter of the port, and then I blew compressed air through the port and had a strong blast of air coming out the other end. This was the primer bulb port that sucks fuel from the float bowl. Then I applied a new welch plug from the overhaul kit. I may still end up buying a new carb before this is all over, but this carb is such a simple design, I really don't understand why it is not performing as new.
5. Lastly, I replaced the fuel hose before I ever attempted to start the engine the first time.
Thank you for your ideas, keep them coming!