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Is pedal hard at the end of the throw? If not, I’m not convinced you don’t still have some small amount of air in system. Given the increase in MC bore and likely somewhat compromised MC, the pedal travel should have reduced some from what it was. The ram isn’t consuming fluid flow so for...

Great news! How far is the pedal moving? The front pot (closest to radiator) isn’t the bigger of the two, at least it looks that way in the pictures? Edit, the deeper aspect of the pot was throwing me off, I see now the volume created by the partition makes the front pot smaller

Don. thanks for reply, sorry for slow response, am in LA with the fires and needed to attend to some things. Sending you a PM.

Do you happen to know how far the pedal moves? Wondering if a different seating seating geometry affects things (I may need to read more of that paper I posted in other thread)

Thanks for the reply, I was doing my math based on 150 lbs of foot pressure (maybe high given HB assists in play), pedal ratio of 6:1, and 15 degrees of off axis push. That gives 250 lbs of side force on the input rod assembly. Looking at attached picture, I’m struggling to understand how...

Was wondering if you have any thoughts on how detrimental some side load is on input to HB.

For any of us using a HB directly connected to the OEM brake pedal (like at least me), we're not getting a bunch of stroke out of the HB and MC. OEM 6:1 pedal with 3 inches of travel is only gonna move the MC 0.5", and that's for a system with little gap in pushrod, etc. It would take 6...

In the pic with the steel rule, is the 5.5" from top of MC measuring to centerline bore of MC? And one more, look's like the pot closest to the firewall is the bigger one, is that the one you ran to front brakes?

Sandmann3, so glad to hear your shoulder is better. Please PM a price shipped to 94306. Bought partial parts kit from you years ago and may stock up.

Your inner fender liners are long gone! ;)

Agreed on larger bore will help with pedal feel. And getting my on pedal ratio sandbox - I think getting pedal ratio down from factory 6:1 is another knob to turn.

Don’t think body lift plays into MC to hood clearance since firewall that the MC is bolted to goes up with body lift and so does the hood?

One thing we haven’t touched on with respect to pedal “touchiness” is the the piston size in the hydro. They come in a ~1.6” and ~1.8” diameter power piston.

Rockauto shows both of these MCs for diesel with HB, you running one of these MCs? If so, do you know if they have the usual 3.4" bolt spacing for GMs? ACDELCO 18M742 ACDELCO 18M949

Be sure to check you hood clearance and the the taller MC will fit. I was looking as some of those and it was tight for me and I have non factory hood.

you have napa close? This MC is what power brake 1977-1982 C3 Vettes had installed and has shallow MC cup so you could tighten up the gap: https://www.napaonline.com/en/p/NMCM2300 Here's Autozone equivalent...

This screams more to me of a bad MC with bad seals on one circuit versus the front pot works better. What that it is unclear to me, willing to be folks like @ntsqd, @Apogee, and @nvrstuk have good ideas. The camaraderie of this forum is great to watch on this thread.

Checking my processing of your posts on this, I had previously understood that the bad line lock combined with 1.25 MC was source of your issues and the 1.33 MC somehow bandaided the issue with the line lock. You subsequently changed the line lock which let you go back to a 1.25 MC and brakes...

Mulled on the a bit last night. I’m leaning towards air in lines. Even with the the config that took all of truck out of loop. When you blocked at MC, did you have slow return pedal? If not, that piece of evidence plus my vague memory of slow return until I got all my air out seems...

Headlights should not flash at all when hazards are flashing. Sounds like a ground issue.