You forced me or I lost my kiss compass, to make a mountain out of a mole hill and to contribute to over think.
I should have known better than to put all of this stuff into the post. It's causing confusion and focus on the wrong thing. My fault, not the readers' fault. I lost my "kiss compass" too! If overthinking was a profession, I'd be a billionaire!
Anyway, you mention the pedal ratio calculation. I put that in my original post, so I'm well aware of that. I'm right at 5:1. That's built-in, and not changeable with the stock pedals unless I fabricate/modify new pedals, or replace them. Stock pedals are cast iron, so that's not going to happen . I can weld cast iron, but it's not something I've done often and I'm not going to bet my life on the quality of my cast iron weld to not break in a panic stop situation. I'm set on keeping the stock pedal assembly, so I have to work with what I have. The ratio should be good enough for a manual application as per the formula, and of course, since it was manual to begin with.
As for my desire to lower the pedal to be closer to the floor, that's not a priority and I shouldn't have even mentioned it. That just complicated the conversation. I was only using it to point out that I think there is either something wrong (because the old brakes didn't require that much pedal travel) or if there is nothing wrong, is there a way to change this with brake line and M.C. changes. As a side point, I understand what you're saying about shortening the pushrod. That wouldn't change the stroke length that the M.C. piston requires, but it would affect pedal travel since the pushrod mounting point travels in an arc, and not a straight line. But this isn't the focus point of what I'm trying to accomplish.
At this point I think I'm just going to re-plumb the entire system with 3/16 line, and re-use the 1" M.C. If there is no difference, then I'll buy a 1 1/8" M.C. That for sure will move me the direction I want to be. My leg should still be strong enough for the bigger M.C. I still wonder, though, if there is something wrong with my current M.C. It just doesn't seem right that it requires so much pedal travel to reach enough pressure to get good braking, and it doesn't seem firm enough. Even my brake light doesn't active until the pedal is pressed quite a distance. After the extensive bleeding I've done, something just doesn't seem right. Maybe it's just a result of the disc/Huck combo and will be better when the Colorado rear is installed. Who knows...
Since Jerry mentioned my "odd" manual disc/drum setup, I'm wondering if this is really a problem? I don't see how a booster changes anything other than requiring less pedal effort on the driver's part. It won't change pedal travel or fix any of the issues I'm concerned about. It would just be easier on my leg I would think??
Anyway, thanks for engaging in my over-thinking!
