I did finally get it lined up. Probably took 10 times or so.
What worked for me was - with the belt on, set the crank ccw 1 tooth from tdc. Remove belt, align ps cam, set ds cam one tooth ccw from alignment. Install belt starting with ps cam (clipped) -> wp -> ds cam (clipped) -> idler -> crank -> tensioner. Apply tension. When I spun it by hand the marks came out dead on.
I still have the WP rubbing problem, although it appears to be VERY slight. My plan is to remove the belt again and give the wp some "refinement" with a dremel tool. Obviously the best option would be to find a part that fits correctly, but after a week in the garage time is critical and I see no reason removing ~1/16" of mat'l in a couple places would cause a problem. I THINK I can reset it in one try now, even though I hate the thought of backtracking after 2+ hrs of trying to set it.
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