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I'm looking at the Hayes manual for "how to mount caliper to fork". Oddly, it doesn't seem to specify how the pad offsets should be set, so that may explain why you have ended up with the outer pad all the way out. I suggest this: Wind inner and out all the way out. ...


Your problem may be that you're misunderstanding mechanical disc brakes. On most, only the outside pad moves, the disc is bent onto the inside pad. This means the loosen, clamp and tighten method doesn't work. You can do it by eye, or use a spacer between the inside pad and disk when you tighten it up. Hayes install instructions are here.

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