BigB; Are you absolutely sure the pistons are absolutely retracted. Sometimes on used , in service calipers, when you squeeze the pistons back, they push a small amount of debris back which piles up between the piston and the casting, preventing the pistons from fully retracting. 2nd; are the rotors the factory correct thickness? 3rd; maybe the pads are too thick. Im assuming the test was done trying to fit the caliper onto the rotor and the slider bolts were fully removed, and that there were no thick asbestos type stick-on insulators on the pads. The oem type was a thin steel film.