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I wasn't setting them up using card or anything. Just adjusted dials until they rubbed, then backed off...
Sparky-
It's something like you slip a business card between the inbound pad and the rotor, then squeeze the lever and it puts the caliper in the right position, the business card creates the clearance for the inbound pad.
Personally I just dial the inboard pad in a bit, squeeze the lever, do the bolts up and then back the pad back off.
Most important bits to bb7 in my experience though are, compressionless cables and arm fully returning.
Sorry if this is teaching you to suck eggs but if you're using drop levers, you are using bb7 road calipers not bb7 mtn calipers?
M_V
Are you using the tri align washers still? Maybe consider switching them out for some flat washers if your disc mounts are sufficiently aligned (the ones I welded onto my Kona myself were so chances are you'd be fine to do this).
I take it you know the deal re letting the arm fully return to the rest position, adjust lever feel with the red knobs etc and the tricks with bits of card and stuff to set up the caliper position?