Front axle out of line

The reason I mention it is that on mine, the tubular outrigger was a good half inch out of place

Just a thought, but are you sure its the axle out of line? Do the hockey sticks look like they're off to one side. Could it be something like miss matched (ie different on one side to the other), hubs, stub axle, discs swivels etc. I know the 300tdi on hubs were thinner/different, but not sure if the overall length from axle housing changed.
Also know you've probably checked this, but you haven't got one wheel spacer fitted have you?