I met with Babbitt Bearing near me to discuss. He indicated yes...this is horribly off and that most likely the cause is the pinion depth...in particular the races may not be seated fully. This is causing the 15-32 shim range I have tried to be horrible, when usually 25-27 is appropriate. So I will pull it apart again...and pop the races. Check the seats and make sure clean. Re-seat and go from there.
Thanks again for help from folks at Babbitt Bearing in Columbus Ohio. 614-279-3031.