Quote: Pedal height - just to clear up what I mean. The pedal is physically at the right height, up tight against the brake light switch. It just does seem to grab until about half way down and then can't push it beyond 75% down - hard as a rock.
So the whole time you push the pedal its filling up the system because you haven't used the valves as advised. Start there.
When it gets "hard as a rock" is it possible you've totally compressed the cylinder in the m/c ?!?!?
What about the pushrod, what are you using and is it in full contact in the m/c with the pedal at full height? This can be an issue because the m/c spacer plate is a good 1/4" thick or more. Keep in mind the pedal ratio here - if there is even a 1/8" of play in the pushrod it will take almost an inch of pedal just to take up that slack! On the flip side, are you sure that the pushrod isn't preloading the m/c ??
FWIW you want the pushrod in the m/c, bolt the m/c to the firewall then crawl in the car and install the pushrod to pedal bolt without having to move either the pedal or the pushrod to make it fit.
