Excessive pedal travel on rebuilt S callipers, but car stops fine Options

[phillstek]

Just finished rebuilding the front callipers with new pistons and seals. Bled them 3 times including power bleeding but the pedal just won't come up. It feels like half the available pedal travel is in free motion before the brakes engage.

Car stops without pulling or locking up and the pedal pressure holds when stomping on them but I would prefer to have the pedal engage pretty much as soon as I hit them.

Any suggestions on possible cause and what I need to do to fix it?

Thanks

[phillstek]

Thanks for the replies.

Have you bled the MC? Yes.

Is it a nice firm pedal once they do engage? And is it a freshly rebuilt pedal cluster? Yes and yes.

Does the brake pedal return all the way? Yes

I rebuilt the rear callipers about 2 years ago and replaced the brake lines, re-bushed the pedal cluster and installed a new b/f reservoir as well. I don't know why but I left the fronts callipers alone. Brakes were great for the first 250 miles of driving with proper pedal feel etc. The pedal went bad when taking the car for an extended road test and required pumping to get pressure and the right front was wanting to lock up when applying the brakes hard.

Determined that both fronts were leaking and discovered some incorrect pistons had been installed earlier by someone unknown. Got some correct replacement pistons from PMB, put those in along with new seals, pads and rotors.

The car pulls up really well without pulling left or right it's just that micro second of doubt when hitting the brakes and thinking "are they there"

I'll do a full inspection on the weekend and see if I can work it out.