After going from front drum to front disc, I have alot of travel in the brake pedal before it reacts. I have bled the brakes numerous times with the pedal pusher method. When the car is off I can press the brake pedal 2-3 times and it gets real stiff and wont move anymore but when I start it the pedal goes down about 3-4 inches from the floor.
I thought there was air still in the system but I don't see any air bubbles in the clear tube when bleeding.
There could be some adjustment needed to the rod length that connects your pedal to the booster/master. I haven't gotten that far yet in my project, but I would double check that you don't need to lengthen the rod a little bit.
Oh, my mistake. I was thinking you had changed the booster, or gone from a non-powerbrake setup to power like I am. If you didn't have to disconnect the rod for your project, then disregard what I said earlier.