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IF you tear apart your old booster, or look at the overhaul manual diagram for like a '72 vette which covers all chebby for that year except trucks.....you will find there is a tough little spring between the input shaft and the output piston to the m/cyl.....that is what allows the pedal to go to the floor like it does....in the vettes anyway....
I did a direct A-B comparo when doing my install, I removed the m/cyl ,....left it hang by the lines, tied up to the fender.....changed out the booster, and rehung the m/cyl without ever touching the brake plumbing one damn bit.....it went from soft/squishy on the floor brakes with WAY too much pedal travel, to rock solid withing about 1-1.5" of travel.....
so you explain to me how my observations are rong......btw, I had a 1.25" truck master on there trying to cure the design problem.....and it helped slightly, but I had to go back to a stock bore m/cyl so I had SOME pedal travel, and modulation abilities.....
Darn it, Gene. You're going to force me to go home and take apart my spare booster now.
If I had to guess, I would bet that you had one of the push rods out of adjustment. But not having been there its tough to say for sure.
Mine works great with the outlets plugged.So Im going to call the booster and mastercylinder good.I think my problem lies in the air getting trapped somewhere.I don't know if its dot 5 giving thats giving me fits or not.I have boiled it.I let settle for an hour before hooking up the pressure bleeder..I'm tempted to spend the money and replace all the seals,flush it out and try dot4.I'm going to put a new set of SS flex lines on it.The old ones are a little over 5 years old.What the heck.Only thing that hasn't been replaced.