In reply to r.greaves:
Sounds like the shifter end of the cable isn't seated correctly in the shifter or is perhaps the wrong style cable end (does it fit snugly in the shifter?) or there is something wrong with the routing of the cable.
Did you replace cable outers? Its easy when cutting them to crush the ends and leave a burr that a cable to catch on occasionally. If you didnt replace them, they could be full of crap thats causing the problem.
To test the shifter, attach the cable to it, and apply tension on the cable without threading it so the only thing in the sytem is the shifter, the cable and your hand. Do the levers act like you expect? On my 105 shifter (a double) when the shifter is in granny ring position then the small lever moves the full throw without any indexing. I only get indexing from the big ring position or the intermediate "trim" position if that helps.
With the cable detached can you manually move the deraileur through the whole range of movement does it move without any noticable change in force other than what youd expect from compressing a spring? Check for stones/grit in and around the moving parts
...desperately trying to remember the name of the good website written by a cyclist that died a few years ago named after the cyclist (its a slightly unusual name iirc), he goes into really good detail on how to solve front deraileur problems... some one put me out of my misery!