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Switch back the front MC to either the 5/8th or to a .7. The jump in piston area from a .625 to .75 dia is BIG, so it is no surprise at all that he hasn't got the leg for it! I've NEVER seen a successfull brake system with both MC's the same dia - you need the smaller dia at the front to get higher line pressure at the front - the bias bar alone cannot give you the necessary difference.
Scotchbrite usually is sufficient, but not always (it also is tough on the wrist, a 3" air disk grinder is the way to go, with LOTS of new scotchbrite disks) - it depends on the compound material that was used. On most high metallic compounds, you actually have to remove about .010 on a lathe to get below the affected zone.
CHANGE THE MC"s !!!!!!
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