Clutch master cylinder problem was a stuck forward piston and the connecting rod had come loose from it. Of course the new cheap master cylinder that I bought leaked around the outlet port so I ended up with the old one reinstalled.
All of this has led me to a bigger problem. When I originally installed the clutch, I ordered a "M-Pact" brand clutch kit from Rockauto. I don't remember what the exact airgap was with the slave cylinder that came with the kit but I remember that it was slightly less than 0.15 with a ZZPerformance spacer (not sure if I realized they had two sizes at that time, so not sure whether I checked it with 0.20 or 0.25 spacer). I went with the "kit" slave instead of the GM slave that came with my new transmission since the compressed length was slightly taller. I didn't really think at the time, but that wasn't a good idea since the extended length was about the same. All of this leads to the slave blowing out while I was bleeding it.
I pulled the motor and transmission yesterday and the air gap with the GM slave is slightly above 0.50. This means that with a 0.25 spacer I'm still at an air gap of 0.25+.
What are most people getting for an air gap with a new clutch?
I had my flywheel turned, what are the chances that a new flywheel would help?
What are the chances that a gap of 0.25 will work?
Any thoughts on whether the ZZPerformance spacers can be stacked, although 2x 0.200 will put me on the tight side with a 0.1+ gap.
Follow up: ZZPerformance recommends just a single 0.25 spacer and thinks the 0.25 air gap will work.
Any suggestions would be appreciated.