just to let you know, some of the better coolers out there are only ~$75 (b&m). The expensive part is the AN lines and fittings...so if you are going to bother installing them, you might as well install a new cooler.
that one's a little more difficult to use, but it is probably the best resource to have for these cars (especially when re-assembling a car from scratch)
where did you insert the CSI into the ffim? Did you install it at a central location or near the throtte body outlet (as on the MK3 manifold, it is central AND at the outlet of the TB to allow for even fuel distribution)
the difference in caster is the likely culprit. these should be close to the same to prevent pulling. with that said, uneven caster won't cause any unusual wear. As per the TSRM, caster difference between sides should be +/- 30'...
Here is the update, I'm not making these. Due to the angles involved, it is way too expensive to have them machined, and I would never get rid of the number of castings I would have to have made to break even.
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