Hate to admit this but the toe-in issue was all my fault. For some stupid reason I got it in my head the outer tie rod end mounted from the top of the knuckle on the ball joint. I "made" it fit. Guess what - the change in angle caused the toe-in. No one to blame on that one but me! So anyone else thinking of doing front end work - get a manual and take some pictures.
Only consolation is it drives like new now.