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Phil
You may need a stiffer return spring or maybe two concentric ones like are used on throttle return.
I'm not sure that a little light contact with the clutch fingers is necessarily an issue as long as there isn't any load on it - maybe some others can weigh in on this???
I know that as long as the pedal travel is in the ERA setup, unless you adjust for very minimal free play, you have to shove the pedal nearly all the way to the end of the foot box to fully stroke the slave cylinder and disengage the clutch.
Are you pretty sure you have all the air out of the slave cylinder? I had some problem with that until I realized I did not have the cylinder rotated in the housing to where the bleeder screw was right at the top.
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