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If you have excess pedal travel, you have excess fluid travel. Ether you are compressing air or the shoes/pads are pulling too far away from their stopping surfaces. Sounds like you eliminated the master as the problem. Are you sure the pedal is coming all the way back to uncover the compinsating ports in the master. Pushrod have some amount free play? Master outlets have check valves ( residual pressure valves ) in the outlets? - manditory if the master is mounted below the calipers / wheel cyls.





If all of the above is checked and OK, then it is air in the system. It's real tough to get it all out in a new system.