It's more common for them to be loose and need to have the cover planed down a little to compensate for wear. To my knowledge, there's only one thickness of disc made. If you've got everything inside assembled correctly, you shouldn't be finding any resiostance or tension as you bolt the cover back on.
One thing that occurs is the condition of the splines on the shafts. If they're worn, it will be in a way that new discs will tend to wobble and bind up and not slide in and out on the shafts the way they should.
I don't think it's the case, but it might be that you need the tension of the return springs on the pedals to get them to back off. It doesn't really make sense because both adjustments (brake tension and freeplay) are made against the loop on the pedal (right side) or arm (left), so presumably both your control rods are just dangling at this point doing nothing. If they're not already on, you might try threading the control rod onto the clevis a ways and give it a light but smart rap, which would have the effect of backing the brakes off and see if they'll release and stay off. That whole control rod and adjusting assembly is going to need to come back off on both sides anyway to get the pedals connected to them before final adjustment.
In the end, you might want to wait and put them after you get the pedals remounted. This will give you a chance to look over your internal assembly, too, to make sure you have it together right, as well as to check out how everything slides on the bull shafts.
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