Phatman,

Completely hypothesizing here, but is there any chance that you pulled some cable through the pinch-bolt somehow? (Are these V's?). Are all of the housings still in place in their housing stops?Are you using new brakes/levers/cable? You could have just set everything into place, but I don't think you would notice the amount of slack you talk about.

Just some things to look at that came off the top of my head. Hope something helps.

-Moab