Front suspension suggestions for better tracking

You are right....I need to make sure that I have the correct spindles. The technician mentioned that he had to put a washer on the botton nut after the recent alignment and I totally forgot about it. Obviously I need to start there before I do anything else. I guess I was thinking that maybe there was some variances in tolerances.

Sounds like a washer on the Lower or Upper ball joint nut to Spindle taper hole. The ball joints seem to come with washers for that now. I think the threads in the ball joint aren't cut deep enough and/or spindle thickness varies. If so, it not a deal breaker.