Need some more specifics to help you diagnose... You're in the 2nd gen section, so I'll assume it's an FC we're talking about. Are these the 4-piston calipers or the single piston sliding caliper type up front? The sliding rear calipers on FC's are all very similar design, except the turbos & some of the NA models get vented rotors - which do you have?
Anyway, my 1st guess in either case is one or more sticky calipers. That could cause the pedal feel you describe, and possibly the noise. If you've got the 4-pot calipers, one or more pistons could be sticking in the bores; if it's the sliding single piston type, the slider pins can get jammed up with corrosion.
Also, I'd find another brake shop - it's much smarter (and easier) to drill out those stuck set screws that torching them. Torching risks warping the rotors among other things.
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