Hydratech Hydraboost and brake bleeding problem

[BBC69Camaro]

My issue is as follows:

1. Brake bleeding issue with Hydraboost (shallow style master cylinder for 69 Camaro).
2. Car is 69 Camaro, Hydroboost from Hydratech, C5 Front Disc/Rear Disc brakes from Touring Classics, CPP MCPV-1 master cylinder (with adapter for shallow M/S).
3. Its completely new system. New Lines, Master and Hydroboost unit.
4. P/S lines are not connected nor has the car been run and had the PS purged of air.
5. Primary (closest to the Hydroboost) feeds the rear brake lines and secondaries (furthest from the hydroboost) feed the front brakes lines.
6. Master cylinder bench bled, has good streams of brake fluid out the primary and secondary on the bench.
7. Master Cylinder mounted to Hydroboost on car has no fluid coming out the primary, and very little coming out the secondary.
8. Brake pedal travel is very limited 2-2-1/2". I think it should be almost double that.
9. Pedal feels like it is stopping hard, there is no give nor does the pedal drop when a bleeder screw is opened.
10. Pedal also sticks and sometimes does not want to come up. It isn't smooth on the return.
11. Measured Hydroboost pushrod to M/C pushrod clearance running about 0.050" clearance (aimed for 0.030-0.060")

Seems like I can't depress my pedal enough to depress the M/S piston to push fluid down the lines (least the rear / primaries). Tried for over an hour to manually bleed (slowly push down pedal then open bleeder screw and close then slowly release pedal), no fluid was flowing down the primary to the rear lines. Tried gravity and vacuum bleeding as well no luck.

I cracked each fitting on the rear line (I have a 2 piece rear line). I had a little fluid dribble out of the union at the frame rail, no fluid at the hump over to the diff.

I doubt any fluid is getting out there, I mounted the M/S up on the hydroboost but didn't connect the brake lines instead left the bench bleeder fittings in and the hoses up over to the reservoir. That way I could see what volume of fluid was being passed. There was 0 fluid going to the rears and very little fluid going to the front.

I think its either a pedal adjustment issue (wrong hole on the brake pedal, I used the lower one), or something with the pushrod in the Hydroboost not putting enough pressure on the M/S pushrod.


Any ideas or help would be appreciated.

Thanks a bunch!