I have the same system on my 512 CI , I cannot affrd EFI .
The disintegration was just a suggestion , I set up an AAR back in 78 , it has changed hands 3 times but is has not been touched since & never has a problem , others I have seen with similar problems you are having needing the needle & seats cleaned constantly but why ?
Holley has approx 20 different types of needle & seat assy , some are viton some all metal in different sizes for increased fuel flow possibly switching them out would help you . Make sure the floats are not leaking & holding fuel although I doubt it as it is not the same carb with the problem .
The problem with setting the levels is when you adjust down the fuel has nowhere to go so you need to set it low to push out some fuel & adjust upward but if it over full this is not the issue .
The EFI system I built I use 3 fuel lines with external fuel pumps in line , 2 - 3/8" lines forward with a Walbro inline pump in each & connected 1 to each fuel rail , then I twinned the return line into 1 - 3/8" line back to the tank , we dynoed this at 702 gross HP with a single 1200 cfm T body