Only thing I can think of is that the inboard pad is not properly seated. Does look awful close to the guide pin(caliper bolt). On my Burb, and my caliper looks like yours, the tolerances are close enough that the caliper with new pad set won't sit down on the hub and rotor unless the piston is completely retracted. Disc brakes have close tolerances like that to keep road grunge from getting between the pads and rotor. Maybe there's a little rock or something else stuck on the pad surface?
It's gotta be something simple that we're just not catching. Hang in there and good luck!
When I redid my Burb front brakes and upper ball joints 2 years ago, had to replace calipers and hoses, and a new set of pads. Also had to replace the ABS sensor package on the splash shield, because the brake locked up and caused it to catch on fire. Not fun! So to replace the splash shield assembly, I had to pull it down to the spindle. That's how I saw the ball joints were toast. As far as the calipers and pads go though, everything is fairly simple. The parts are designed to be assembled one way(easier for the factory to build them and for us to repair them too). Wish I could be there to help you reassemble it and go over everything, but unfortunately Houston is a good way from East Bay Cali.....
