Clutch pedal and Z bar help

Another thing that would throw you off would be the height of the throw out bearing. Diaphragm clutches typically need a longer bearing than a Long or Borg/Beck style pressure plate (but if you bought as a kit it "should" have been matched). Just a thought there. Your linkage should have round holes, you could be losing the 3" of pedal travel just in worn linkage/sloppy z-bar, maybe even worn bushings in clutch pedal.