[Lynn]

Pat & Scott M - Can't move the bottom out to match the top. Notice the last sentence in the problem description: "The bottom A-Arm has a fixed position ball joint, so I really can't easily manipulate the position of the bottom attach point of the upright."

Scott C. - If new A-Arms are built, they will have rod ends on the inboard attach points. If the issue wasn't symmetrical side-to-side, a twist in the chassis would be more plausible. For the time being, I'll follow the Ocham's Razor rule and assume that there was a simple measuring error in the construction of the upper A-Arms.

BTW, as designed, the KPI is adjusted by a combination of the use of shims to move top & bottom A-Arms forward and aft, as well as, the in-out adjustment of the upper/outer rod end which also has a fore/aft component. Indeed, castor, camber and KPI are all affected any changes (including changes to the toe), so you really have to sneak up on proper alignment settings making tiny changes to one thing at a time.