Dont stop posting up these pics. I have to go through a lot of this and am appreciating the insights and issues you are having and how you solved them.
I have the same clutch pedal issue you have. I hope the Alloy welding you have done is going to be strong enough seeing the old pedal is a cast part.
My pedal cluster is a TILTON part. I hope the masters work out OK. I gave TILTON all my info in piston numbers, sizes, car weights etc etc for them to work out the master sizes. The cheif engineer at Tilton was very helpful