Double check the length of the pushrod between booster and MC.
If it's say 7/16" short then you might indeed have over 2-3" of play at the pedal.
The honking sound (not sure I should be answering this... ) is perhaps coming from the booster which forces the displaced air out somewhere. Most likely through its one-way valve.
Perhaps a bit late in the season but maybe tomatoes will still do allright this year.
