OK, After installing the 13/16" master cylinder for the HTOB I found the sweet spot as far as adjustability for my set-up. While the pedal pressure has increased a bit from the 3/4" MC, its not too much for my young left leg. I may have a different view 10 years from now
I am able to have the clutch disc begin to engage with my pedal about 1 inch off of the pedal stop as its rising up from the floor board. The total HTOB travel I have is about 0.600 inches with the pedal fully depressed to the pedal stop. Shifting is smooth into all gears.
So the root cause here was not a stuck disc NOR air in the system (Im an expert in that task and can fill a new system and have it bled in about 10 minutes tops.) It was simply not enough HTOB travel using the 3/4" MC and my clutch pedal geometry as designed.
I also installed an aluminum coated heat protective sleeve (from DEI) along the complete length of the clutch fluid feed steel line to keep the heat from the headers from boiling the fluid in the clutch line. The next mod I'm doing is to form a basic heat shield that mounts to my master cylinder to keep the header heat from heating up the fluid in the MC. Well...... that sure was an education in custom hydraulic clutch set-ups, if I did this for a livin Id starve.. !!.
but its set up right.