[kitcarbp]

ROADROD, Your math is right. On my long D.C. area commute home last night (and after reading other Mcleod clutch users posts, it occured to me, that I dont have enough Mcleod 1300 series HTOB movement yet. Although Mcleod states "0.375" Pressure Plate finger travel required" I believe that is for "initial" disc release, not "full" disc release, thus that is why my disc is still dragging on PP and not fully released @ my measured 0.390" HTOB piston movement. I think I get it now.

I also found an email from Mcleod on their web-forum where they expect FULL disc release at 0.500" HTOB piston travel, thus, now I see is the source of my confusion. If I would have been a little smarter, and drilled a hole on the bottom of my OEM bell housing, I would have seen that I dont yet have the desired 0.050" air gap between PP and disc at 0.390" piston travel.

You are spot on about 3/4" master and the bolt on HTOB, I wont over extend it with 1.0 or even 1.1" of travel with my current clutch pedal geometry after looking at it upside down via my mirror under the car last night.

I also realized the kit builder (West Coast) installed the clutch pedal stop after years of selling some cars with 7/8" Masters (For Tilton HTOB) that would in some cases over extend the HTOB (slip-on style) bearing if used on a Mcleod HTOB without a pedal stop. When they started supplying pedal stops on the kits, they also realized 3/4" masters are a better choice for pedal effort and preventing over-travel, they left the pedal stop in place (which I now realize was likely intended for using a 7/8" Master to protect from over-stroking the HTOB and leaking. I will now remove the pedal stop (that will give me another 1/4" of pedal travel and move that HTOB piston travel closer to 0.500" I think.

Thanks to all for your posts, its becoming more clear to me now. I love this Forum and could not do this project without all the help I have received.
I will report back in the next days.
Bill