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.