Surely what you're describing is a fooked rotor? Get a new one, set the brake up once and you're away. If I understand what you mean by Avid's 'tri-align' system correctly, all you do is loosen the bolts, pull the lever in and do the bolts up and hey presto, nicely set up brake. Not that I've ever used a BB7 before but that's how my Hayes post mounts worked.