Folks,
For anyone still following the thread, or who might pick it up looking for a similar problem, I think I DO finally have an answer to what is going on.
I have put another 100 hrs or so on the clutch I did earlier in this thread, and it was starting to do the same thing (running out of adjust to stop dragging of the clutch). I found a place that rebuilds clutches (KY clutch) and sent them one of the previous pressure plates and disks to see if they could modify one or both to make more 'room' in the adjustment (like turning down the clutch disk).
They just called and said the pressure plate was junk. The rivets that hold the clutch diaphragm spring and the assembly together are 'T' shaped. Under the 'T' is one of the pivot rings for the spring. He said the rivets were 1/2 way worn through where the ring contacts the 'T'. That would make a huge difference in the 'throw' of the pressure plate itself.
They are putting new rivets in and taking .010 or so off the plate to give the extra room I wanted in the adjust. Apparently, the rivets were too soft for this application or something. I would have thought there would be essentially no movement of the ring relative to the rivet (because the spring pivots on the opposite side of the ring), but there must have been enough scrubbing to wear the rivets. I put one of my other old plates in a vice and compressed the plate a bit, and could see where the wear was happening on the rivets.
I NEVER would have thought of this as the cause of the problem!
Thanks again for all the thought you all have put into this!
Terry