I don't think you did a good enough job cleaning the inside of the battery connectors and the battery terminals. Smoke from heat is due to a bad connection and you can't "see" bad electrical connections most of the time. Likewise the battery should be recharged and "load tested" to make sure it's good at the auto store. Use the wire brush below for easy battery terminal maintenance.
PS Like Carl says below, it's always possible you have a big short circuit on the starter motor connection to the battery.
http://www.jcwhitney.com/autoparts/Search?catalogId=10101&storeId=10101&sku=battery+brush