I have a suspicion they couldn't get the caster dialed in exactly the same on each side, and I'm feeling the results, especially due to the lack of caster.
A general lack of caster won't cause it to consistently pull one direction. That's just an incorrect alignment.
I can't seem to wrap my head around why this is such a PITA issue even with the offset upper bushings though. I'm going to wind up getting some degree plates and one of those caster/camber tools to do it myself, but I have a suspicion that not even the offset LCA bushings are giving enough benefit.
It would be nice - if only due to cost - not to have to throw tubular UCA's on these cars just to get good caster in a reasonably repeatable manner. And I don't mean the fully-adjustable ones either.
-Kurt
There are a couple of things going on here. One, the original suspension was designed for bias plys and the alignment that goes with them, which is the opposite of what you need for radials. That's why the offset UCA bushings come into play, and why you need tubular UCA's to get a good amount of caster. The stock UCA's were never intended to get more than +1.5* of caster. In fact, as you can see in the factory specs, manual steering cars were supposed to have negative camber from the factory. Bias plys.
Given the advances in technology, it's pretty amazing the stock suspension components can be used at all with modern tires with just a bushing change. (but they can!!!).
The second thing is that the suspension geometry changes with the ride height. This is true for ALL suspension systems. But, because the ride height on these cars is easily adjustable, it means the suspension geometry is easily changed too. This is a good thing, because it makes it easy to lower the car and adjust the geometry to work with radial tires. The camber curves, bump steer, roll centers of these cars can be adjusted to work
very well. But it has to be done
RIGHT. Otherwise that adjustability just makes it easy to screw up the geometry to a point where you can't get decent alignment numbers.
Offset UCA bushings work great (to a point), and you should be able to get as much as +3* of caster with them. But that does depends on where the ride height is set, which means that it's not necessarily repeatable from one car to the next unless the ride height is the same between the two cars.
Before you condemn your stock UCA's and offset bushings, you need to set your ride height where you want it and have the car aligned again. It sounds to me like the alignment shop you used had no clue how to deal with your car. Which is pretty common, and pretty sad because these cars are SIMPLE to align. As of right now, because of the ride height change,
none of your numbers are what they were when it was aligned. A 2" drop with the torsion bar adjusters significantly alters the geometry.