Hi,
I just replaced the entire braking system with all new rotors, pads, calipers, lines, hoses, speed bleeders, brake booster, and master cylinder. All parts were sourced either NOS or rebuilt "according to SVO specs" from reputable sites like Maximum Motorsports and Stillen who have experience with SVOs, except the brake booster and seals that came from NPD - M-2005-3A, rebuilt E1BZ-2005-B.
My problem is that on the test drives (after bedding the pads) the pedal travel before the brakes start to engage is around 30% and as I hit about the 60% travel mark the brakes will stop the car better than ever. However, the lack of progression in braking power until I am over 50% travel is worrisome. At the end point the car stops incredibly well but it is scary getting to that point. Almost like every stop has to be treated like a panic event.
We have bleed the brakes three times, checked all the lines for air or loose connections, and even tried the old brake booster which resulted in pedal travel to around 70% before the brakes started to grab. I took the car to a local shop yesterday and they could not find anything "wrong" with the installation or setup but agreed they do not think the pedal travel is correct. Idle is normal and according to the manual the vacuum lines appear to be installed correctly. I cannot hear any leaks but considering the noise under the hood I might be missing something.
Any ideas or does this seem normal for the car?