My buddy and I checked some things out on the old pickup last night hoping to solve the problem without dropping the tranny. We didn't come up with anything except a list of what it's not and what it could be.
Here's what it's not:
It's not air in the system
It's not a clutch fork throw problem
It's not a fork geometry problem
Here's what it could be:
It could be the input bearing retainer bottoming out on the clutch disc
It could be the input sticking on the crank (doubtful but not ruling it out)
It could be the input shaft bottoming out on the pilot bushing.
It could be something in the tranny
It could be something with the clutch itself
Looks like instead of enjoying the truck at the show tomorrow, I'll be tinkering with the tranny and trying to figure out what's going on. Oh well, that's hot rodding