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Update: so I just came back from playing with it again. I swapped back the stock slave cylinder, and the situation got better, I managed to drive the car, but shifting is terrible. I can feel the clutch is barely lifted, and at 1st gear with clutch depressed, the rpm dropped and the car violently wants to go forward. scary!!
It is only a few mm difference!
I got everything figured out now. Simple physic, more pressure means more compression. A lot of you might have ACT heavy duty clutch, i'm not sure how heavy is your clutch, but I think it is not heavy enough to change the hydraulic compression rate too much. ACT designed the product to work with stock hydraulic system. Indeed, the stock hydraulic system was designed to push the stock pressure plate. When the pressure from pressure plate increases, it also increases the hydraultic compression, and when compression increases to a certain level, your hydraulic could no longer push far enough to push the pressure plate to disengage the clutch. In a way, it also putting a risk on blowing up your slave.
Base on this simple physic, I believe it is necessary for me to get a bigger master (more fluid for higher compression = more slave travel). Since my clutch was originally intended for AE86 local shop and now customized for silvias, i don't believe it was designed to work with our stock hydaulic system.
One question here, I know bigger slave requires less effort to step on the clutch, but what if a larger master? would it increases or decreases the effort to step on the clutch?
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