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I've had the same problem after caliper rebuilds. In my case re-bleeding improved the situation a little, but not a lot. My mechanic recommended putting pressure on the pedal and leaving it overnight, i.e. depress the pedal with a suitably sized piece of wood and wedge it between the seat and the pedal. This improved it a lot. A bit of spirited driving improved it further.
The reason for the problem is (I believe) that the new dust boots are initially not fully seated and pull the piston further back than normal. You then get longer than normal pedal travel. Once the boots are fully seated, the problem dissappears.
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