[Walt Fricke]

What about adjusting the rod from the pedal to the bellcrank? It sounds like your linkage is causing the piston in the MC to be a bit forward. Doesn't take much movement of the pedal to cause the vacuum boost to start boosting.

I know what you mean about adjusting the actuating rod, though. I tightened up the brake system on my '62 VW once, and when things warmed up the brakes were dragging. There was a play spec for that.