Thanks for your response. It's possible what you are saying is correct (and I for sure needed to tighten up the rear drums, thanks for that advice).

but just so I am clear in what I'm saying the issue is: If I disconnect the push rod from the pedal, and insert it by hand into the MC - I can feel where it "hits home" and actually engages the MC, which would be (I would think) the start of braking action.

When the rod is in that position, the other end of the push rod (linkage end) is at a specific point in space. That is the same point in space the pedal connector point comes to after traveling the approx 3 inches of pedal 'slop'.

So it would seem to me it isn't (yet anyway) a function of not being to move enough fluid, it is either 1) too short a push rod, or I guess possibly 2) the MC or the pedal are in the wrong spot.

What i'm calling 3" of slop travel in the break pedal seems to translate to approx 3/4" of linear travel where the push rod is just floating in air (supported by the rubber boot) not even pushing against the MC piston.

Thanks again -