Quote:

and then calculated the movement of a single piston with that volume with an area of 17.2 (4.3 sq in per caliper * 4 calipers).
.5752 / 17.2168 = .0334" of movement





There's the hitch in your getalong. You should only look at one pair of calipers.
The master cylinder has a single bore but it is divided into two sections. One for the front and one for the rear.
In effect, it's a separate master for the front and another for the rear.


Quote:


Note: I then checked the math in excel, calculating the volume of a cylinder for four 44mm cylinders and four 40mm cylinders:
((44/25.4/2)^2)*3.14*.0334 = .0787
((40/25.4/2)^2)*3.14*.0334 = .0651






There's hitch number two. You do not use both side of a multipiston caliper. You only do one side.

Quote:


BTW- your total piston area in the front is ~4.4 sq in.




The original 2.75" calipers on my Imperial (and several other cars) measure 5.9 sq inches.


To determine if the MC is too small, look at the pressure generated vs the pad movement.
High pressure at low movement = too small.
Low pressure at high movement = too large.


We are brothers and sisters doing time on the planet for better or worse. I'll take the better, if you don't mind.
- Stu Harmon