I should have been clearer.

Originally Posted by red58
"mechanical slack" will affect the travel on the first push [lower pedal]

This is what I'm referring to. The pedal is hard on the first push, but it will go down to within 4" of the floor. On the second push, it will be considerably higher. More than two pushes doesn't make any more difference. That's what leads me to believe that the excessive travel is from the hydraulic system taking up mechanical slack. The hydrovac is in fact hooked up and has just been rebuilt. I did bleed it per the manual (twice) and I'm pretty sure that there's no air in it or anywhere else in the system. I dunno. Maybe I just need to get a fire lit in the powerplant again and drive her around a bit. Maybe once everything seats in I can get things adjusted a little better.