Also, did you go over your k-member really well before you reassembled the suspension? How bad were the old parts worn? Sometimes they are extremely hard to see, but you may have cracks around where the lca pivot goes. That can cause your alignment to be unstable, and might be perfect on the rack but changes when you are driving it.
When I had it all tore down my Dad and I both went over it with a fine tooth comb..found nothing. Next week thursday its going to the frame shop and getting look over and checked for straightness!
