7805 madness - Any ideas?

Hm.. you didn’t adhere to the standard that everybody else is using (especially the manufacturers of those ICs) and used plain numbers 1,2,3.. (or for BGAs A1,A2,A3..) for your LM7805 symbol.
I guess you used VI and VO for voltage input and output respectively.. this is not how this is supposed to work.
If you want/need this kind of information on a symbol use the name field, not the pin number as otherwise you end up with proprietary footprints for each of your symbols..

Keep on reading here: