Paul,
You've gotten good advice from the fellas and I doubt that my explanation will help much but I thought I would at least try to offer something as I have had about the same type of trouble in the past.
Here's my tank set up for Sullivan plastic tanks:
*Copper line going from the -top -(inside) of the tank bent and exiting straight out through the cap and extending 5/8" out past the cap. Fuel line attached to this, turned down and routed to the muffler for pressure. I use a strap to secure the tubing below the bend. Don't over tighten the strap! This line also serves as the overflow. Disconnect when fueling.
*Copper line from the -bottom- of the tank bent and straight out 5/8". Fuel line goes up and above the fuselage (1"). Same strap set up.
*Copper line -straight- into tank extending 1/2'" (from the stopper) into the tank and 5/8" beyond the cap outside. Flexable fuel line supplied with the tank with sintered bronze clunk and attached to the straight, copper tubing inside. Fuel tubing outside on this one to the NVA. Try to keep the fuel supply line oriented to the middle of the tank.
Make sure the clunk moves freely in the tank. Clunk should be about 1'8" from the back of the tank. I cut small (1/4" long) pieces of the tubing supplied with the plastic tanks to secure the flex lines to the copper inside and out. Cut off a piece of the smaller tubing, slip it over the ends of a pair of forceps or small needle nose pliers, open the tool to stretch the piece and slide it over the fuel tubing. Slip the fuel tubing over the copper tubing and clunk and slide the retainer piece over the fuel tubing and copper. Do that on the copper exit points and the NVA end also.
I cut a 1" long piece of copper tubing and slide it 1/2" into the fuel fill line. Leaves 1/2" extending out of this line for filling the tank. Cap off the copper after filling.
I've had good success with this set up on both on profile tanks and tanks mounted inside the fuselage. Works fine with or without muffler pressure.
As a side note, I had one Super Tigre NVA that allowed fuel to pour into the venturi even when the needle was screwed all the way in to the seat. Close examination showed that the needle had very light cuts all the way down one side of the tapered end which allowed fuel to run past it. Must have bumped the thread machine as it was being made?
I'm sure the above is over explained and nothing revolutionary but I know how frustrating problems like yours can be. Sometimes it's best to go back to square one and redo everything.
Hope this might be of some help to you. Good luck with everything. I'm sure you'll get it figured out soon.
Regards,
Joe