I felt that my clutch might have been dragging a bit. I made sure to bleed the system well and then I followed Jack's video:
https://www.youtube.com/watch?v=vYJxQyjIhUw

What I'm finding is if the master bleeder valve is blocked, I get a good pedal feel. As soon as I back off the master rod to unblock the valve, the pedal is too light and the clutch doesn't disengage enough to get into gear.

I guess I have a worn out fulcrum ball that needs replacement and/or shimming. I don't know if it's ever been perfect because I never did Jack's method before! I always just adjusted the master rod until it felt right.

That being said, I guess I'm not SOL and just need a bit more travel with these parts.
I'd like to keep the master rod in the right spot, which means I should extend the slave rod, right?
But how can I determine the right length to extend?

Or does it just not work that way, i.e. the master bleeder will always give me a light pedal with this lever geometry?

Your getting a good pedal feel as the slave is getting pumped up/preloading. Don't do the extended slave rod. Your car is a fwd 1g DSM. I thought dropping the trans in a 1g AWD DSM was easy, a FWD is even easier 😊 I'd spend an afternoon and do it right....

I think I understand better now. So the bleeder puts it just before preload. That means extending the slave will preload it and I would be chasing my tail with adjustment again.

Thanks! I'll spend a bit more than an afternoon though

Played with adjustment again.

Can anyone explain why this happens?
It doesn't agree with Jack's instructions.

1. Bleed the system.
2. Pump the pedal = good feel, drives fairly good too
3. Press the slave in a couple times at the fork
4. Pump the pedal = feels very light, not disengaging
5. Repeat

Why does pressing the slave in seem to introduce air into the system? Is my slave shot? It doesn't seem to be leaking fluid. Once I drove 250km before pressing the slave in and it was fine & consistent.

I just did my clutch adjustment using Jack's instructions.
Didn't have issues you were describing. There must be something wrong somewhere, i am sure your fluid level isn't the issue.
How tired is your master ?

Yeah, definitely the fluid is full in the reservoir. I can't find a leak at the master either.
The slave is very old. The master I would guess has less than 50K KM.

How are your lines from master to slave ?
Consider just refreshing the whole hydraulic clutch system for your DSM with new OEM parts.
It's not worth your time diagnosing this old stuff over and over again, there are better things you can do

That sounds expensive, who wants to sponsor me?
Honestly I'm hoping I can sort out the exact cause. I guess I'll start with the slave.

You actually right, i forgot how expansive OEM master is. I was under the impression it's under 100