I'll agree but the OP appears to have all the answers having done thousands of brake jobs throughout his professional career. "NOT his first RODEO". OK I'm done here.
You opined there was air in the system even though there isn't a single indication there is. No bubbles in the system, no surge in the master when the pedal is released and the pedal doesn't pump up to a higher/better location. I've done everything short of rotate the car 90 degree while bleeding. (have had at 45 degrees though) it hasn't changed at all.
No opinion on the unevenly worn pads? There is an problem right there that will cause the described issue even though I don't think that is it totally.
