Thread: Do manual brakes always feel like this?

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A small bore master cylinder such as used with manual brakes will have to travel farther to engage the wheel cylinders. It's a matter of volume. It takes a certain amount of volume to begin moving the pads on the front and shoes on the back. A power brake system uses a larger master with more volume moved at the same pedal travel, but the pedal will be harder if used without a booster. Bigger bore, more volume moved, less pedal travel, more leg effort. Smaller bore, less volume moved, more pedal travel, less leg effort.

I think what you're experiencing here is that you are using a small bore cylinder, so it takes more travel to fill the front calipers than if you were using a larger bore cylinder. Even with a small bore cylinder to decrease leg effort, the front discs take a tremendous amount of pressure and volume to operate properly, completely different animal than 4 drums. I don't think there is any way you're going to be happy with this system. Use a 'vette master cylinder and 7 inch Midland Ross booster together with the correct valving. Contact these guys:
http://www.mpbrakes.com/

That's just my opinion. I could be wrong.