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Don't give up, you sound like a very competent mechanic and are going through the right steps to figure it out. I am assuming that you checked the actual calipers but the chance of all 4 acting up is slim to none. Sounds like the problem is in the pedal or the booster. Did you check the pedal and rod? There is another thread on here with the booster failing and he gets a hard pedal but many people had their booster rust out on the inside. I would at least pull the booster off and the brake rod and have a look, you already have much time invested and this won't take too long.
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