Since I bought my Elf over a year ago, the brakes have never been working to their full potential. I've always had to pump them up before any drive, and then give them a few pumps before they would brake effectively whenever I wanted to stop. I've gone through and replaced all the wheel cylinders that were leaking, so that is no longer adding to the problem. I also found that both the hoses that connect the leading wheel cylinder to the juncture at the bottom of the subframe were collapsed inside or seriously fouled with gunk, and both have been replaced. I've also replaced the hard line that wraps around the front of the subframe and connects the left side brakes to the break light switch junction. All the breaks have been thoroughly bled and the adjusters adjusted so there is light resistance when turning the wheels. When I got the car, the breaks were spongy, but now with all this work they are hard, but still require multiple pumps to brake effectively. When fully pumped up, the pedal travels half way to the floor before they get hard and start braking.

Any suggestions on what to try next? I'd really like to be able to drive this car on a regular basis again...

There are two things I would suggest.

First, remove the drums and look at the orientation of the shoes. Compare this to the detailed pictures in your manual. The friction material is not bonded over the entire length of the steel shoe, it is offest towards one end. This is on purpose. Make sure you have put the shoes on in the correct orientation to match that shown in the manuals or you'll have a softer pedal than you want. Sorry, I can't describe it well, it is represented well by sketches or photos in most manuals.

Second, (and only after you've confirmed the shoe orientation), adjust the drums. Proper Mini drum adjustment means that when an elevated wheel is spun by hand you WILL hear audible drag AND the wheel will stop spinning within about one revolution. If the wheel spins and spins silently the adjustment is way too loose and you'll have excessive pedal travel.

BTW, you're not bcliff's son are you?

I am Bcliff's son.

I have corrupted him!
Bruce