Sometimes you have to go deeper... check to see if the wheel bearings are round... and the axle nut to specs... I have found bent front bearing races on my cars ... at least once...and this introduces play in a direction which is not usually found by other than inspection....
I am also a firm believer,,, if one is having problems , in marking the place which tires are placed on the hub... and trying different spots... also.... when having problems... try a place which balances the tires with them ON the hub, on the car... the way they used to do it...when I worked at a front end place that often took care of the hard to diagnose problems....
A little play in the wheel bearings, a little off balance on the hub and a little off balance on the tire/rim and if they get positioned where they aggravate each other it can sure be unpleasant...
I have said many times that attempting to align without new everything is pretty iffy,,, set the toe in and go on down the road...
You can not even set the alignment to specs with everything new if the springs are sprung... the car is supposed to be a certain height above the road at certain points to be correct....