When I put the brackets on I run a 4 mtr length of material down the length of the chassis to make sure they are pointing straight down the chassis. You will not be able to adjust/shim the toe untill you have the car on it's wheels with the coilovers on, the ride height set and the bolts done up tight on the crush tubes. There is no point in doing this then taking the car apart to paint it, if you get the brackets correct it gives you a starting point to work from.
As you say there is slack in the parts or in engineering terms 'clearance' and due to the all the little small errors built in to the parts it all adds up to the misalinement. You can shim the bearing carriers to correct the toe, as for which direction they should point I always thought RWD cars where dead ahead on the rear and it depends what side of the upright the rack was on the front.
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