I'm not sure of good suggestions, I have always thought the Zcar system was pretty easy to bleed. On my car I had replaced the system a few times and alwyas had pretty good luck. Sometimes when all the parts are new I would bleed it, then run is at low speed for a while to bed things in. I also think this helped rattle tiny bubbles that get caught in the parts loose so they collect. Then follow it up with another good bleeding.

Here is another random thought, are the rear wheel shoes adjusted up and making contact? On my car the adjusters were removed so I would adjust them by hand after each session to keep the pedal nice and high. If I skipped a session the pedal would get pretty low, and I guess if I kept letting it go it would run out of travel at some point. Just something else to double check since I would normally spin the adjusters back when replacing the shoes to make it easier to get the drums on and off.

I have heard of rebuild calipers not having the bolts that hold the caliper halves tight (though I have never seen that first hand). No matter, when I replaced the calipers, I always checked those bolts to make sure they would not spread under brake pressure.

Sorry all I have is some random suggestions to help you spend more time in the garage....

Jeff
- Zcar no more