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Sounds like you have been at this for a while and have tried most methods that should have worked.
When I built mine, I used Tilton M/C and remote resevoirs. I was told that it was extremely important to make absolutely sure that there was no air trapped in the hoses between the resevoirs and the M/C's. Is there any possibilty that you may have over looked this? It sounds like you get the system properly bled, then you get air back in it somehow.
Sorry I can't add more but maybe someone else will have answers.
Wayne
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