Everything back together. Clutch lever is in a much happier place, slave rod easily has enough left on the end for a spring! (so I threw one on, not stock stuff, just some bits I had laying around). Clutch feels good, certainly different, sweet spot has come up quite a bit, still not running the pedal spring.
So I guess this whole time (4 years) I've been running with an upside down throwout bearing, PO installed but then I reinstalled (a new one) the same way, so I can't blame him completely. He got it wrong, I copied him so I'm just as guilty.:tomato: What a lot of trouble compensating for that all this time!
At least I guess that's the issue.
So that's good news. Car runs and shifts again, unfortunately my rear main seal job failed somehow, bummer.