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1. Has anyone experienced out-of-tolerance drums on aftermarket rotors?
Cheap after-market drums could certainly be out or tolerance, but I don't think that would cause the cables to be an inch too long.
3. Does anyone have a trick that might be used to take up the slack in the cables?
Did you check the main adjusting nut? I think it is about 17mm nut, accessed from the back seat with a six or eight inch extension. Once the cover is off the emergency brake handle area, the nut is accessed from the rear direction. You'll see it if you get in the back seat, crouch down and look with a flashlight into where the rear of the emergency brake lever hinges at the floor. You'll see it in their. The nut faces the rear of the car. It adjusts both brake cables at once, so get the two evenly adjusted with the smaller nuts at the front of the assembly before using the 17mm nut adjustment.
Other than that, I don't know what to do. I've never had the cables system completely apart. It sounds like maybe they sold you the wrong cables.?.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 244, 140k , auto.
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