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If he is a savvy mechanic he can smell the difference and knows better then to add Dot 5 to a DOT 3/4 system. If not you are literally screwed.

Look at the illustration on page 277 for how to adjust the brake pedal free travel to 1/2" where it belongs.

These are good examples why the book should be used and referred to during component installations instead of afterwards to resolve issues.

Sounds like either pedal rod (do you still have a rod adjustment) or shoe adjustment to me. It sounds pretty close to correct. You are supposed to have (I think) 1/2" of free play anyway. I need to adjust mine too - I have about 2" of travel! I know, I know - don't beat me up over it. I only drive mine every so often, and can't find the time to work on it.

Pedal free play and shoe adjustment are really unrelated.

The free play adjustment controls the pedal travel from it's upper limit to the point of moving the piston in the master cylinder. From that point on pedal travel not resulting in shoe to drum contact is simply the function of applying increasing hydraulic pressure to the wheel cylinder and this has a feel somewhat stiffer than the first FREE unrestricted 1/2" of pedal travel. This is why free travel is usually adjusting while checking only with hand pressure on the pedal.

Significant pedal travel during the hydraulic pressure generating phase is the result of excess shoe to drum clearance. That distance is reduced by reducing the shoe to drum clearance.