The foam coming up in the reservoir is an indication of air, has to be... Must be getting in around the seal cups in the mc when releasing the pedal. How? Wrong cups, bad machining, bad location of bleeder port, points to defective mc.
I like the idea of blocking off the mc, see if it will build pressure. If it will, move the plug to block the rear, see if it will get front brakes, same with the front. Then you can isolate the problem.
One other thing, remove the mc, check the travel of the push rod. Make sure it is giving the mc full travel.
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