Manual brake master size and problem?

[GregWeld]

Did you BENCH BLEED the master before installation? This is a must do step!

When the car is "cold" -- have you looked (removing the wheels - getting it up on stands or a lift - maybe the night before so you don't have to touch the brakes) at the spacing of the pads? Pad knock-back can act like this -- where the pads retract or get pushed back - and the first pedal action is just moving the pads back near the rotor.... This is usually something that happens when on a track due to deflection of the rotor pushing the pads back too far... but since we're just guessing here -- I'm tossing this out there.

Have you bled the brakes using the gravity method? Or?

Have you put a bunch of pressure on the pedal and just held there for a minute or so to see if there is a change or drop in the pedal?