Chasing a firm brake pedal, What next? Options

[robkammer]

Teeners: It's been over two years since our 74 BB arrived. A Caliper blew out as it came off the transporter in 12 degree temps. Really no surprise as the PPI pointed out a leaky caliper. So I did what I thought would be appropriate for this little beauty, I sent all of the hard bits out, calipers and regulator, to a widely recognized firm for 'restoration'. Put in a new EZ master from 914. And all should have been fine. But, even now, after 1800 miles, a second set of calipers from the 'restorer', a new ATE MC from the restorer. ( I threw out the EZ MC). I still have squishy pedal.
I do not suspect the pedal box area as the car has absolutely no rust.
I just rebuilt the 'restored' front calipers with new square cuts from AA, took out the springy metal pieces that are supposed to keep the pistons from rotating, and the pedal is much better. I have about 50 miles on this but after bleeding it again the bleeders were leaking and I put it back on the lift. ( I was told: maybe: we left the calipers in the acid too long)
So: Now that the pedal seems like I might be on my way to GOOD braking, I can hear the pressure regulator knocking when I press the pedal, at a standstill, in the shop. Is this normal and to be expected? Note: During attempts to bed the brakes and get them working, I was only ever to lock up the rears, and it was really difficult to do. ( difficult may not be accurate, violent might be more appropriate)
The newly rebuilt calipers seem fine, just like the calipers in my 911's that I rebuilt.
As for bleeding, I've done it every way known to man. And some new ones too. Just picked up a 6th quart of Super 4. $26.00!!! A fifth of Weller was only $23!.
I'm really frustrated with this little car. Any input will be appreciated.

I'm thinking of putting in a Tee in place of the regulator, just for testing. If anyone has a Tee that they would be willing to let me borrow, I would be willing pick up all of the shipping just so I don't have to mess with the fab work.
Thanks,

[mskala]

Haven't seen this mentioned yet, but with new seals in calipers sometimes they are strong enough to pull back pistons slightly and this will get better by itself fairly quickly.

[jhynesrockmtn]

Haven't seen this mentioned yet, but with new seals in calipers sometimes they are strong enough to pull back pistons slightly and this will get better by itself fairly quickly.

This is why a couple of us have mentioned bleeding with something thinner than new pads in place. Exactly what the mechanic in Bend described.