If I can pick your collective brains for a moment, the truck has a noticeable vibration a little above 40 mph, which goes away around 48 mph and returns much worse around 62-69mph.
Surprisingly, it gets significantly better if I'm steering slightly to the right, which leads me to believe it's alignment related. I got an alignment before the big trip; everything is clost to spec, but they couldn't get everything quite right without some $15ea OEM washers to space everything out
Would y'all suggest checking anything else? the alignment is so close to spec that I'm concerned it's something else, and since it's so significantly affected by the direction I'm steering (it gets significantly worse on either side of 5 degrees to the right), I'm wondering if there might be something up with the front suspension that I can't place.
It would be pretty helpful to have a better idea of where in the vehicle it seems like the vibration is coming from, front or rear, left or right.
To my mind, here's what I think your vibration might be in no particular order:
1. Front wheel bearings, these are cheap and easy to replace if you're already doing a full disk and pad replacement, so if you haven't replaced those yet, or you feel like upgrading. pick up some new inner and outer bearings and get some fresh grease in there, you'll have the opportunity to inspect the knuckle entirely to make sure it's not worn out or completely damaged.
It's possible that the many bearings in the rear axle are going out as well, but they typically last a lot longer than the ones at the front.
I did mine before going on a huge roadtrip, and while I didn't notice a bad bearing before, i did notice a smoother experience on the highway after doing them.
2. Double check your lug nuts and make sure you're torqued to spec, it seems like a dumb thing to say, but sometimes you never know!
3. Other worn out suspension components, since you mentioned it gets better with steering input, and varies with speed, it's possible you're getting some kinda of harmonic vibration from worn out components that only comes out when the wheels have reached a certain speed. Although, the guy doing your alignment probably would have mentioned something if it was out of whack.
Check these things regardless: Inner and outer tierods, upper and lower control arm bushings, upper and lower ball joints, sway bar links, sway bar bushings, check your rear suspension components for play as well.
4. Drivetrain/driveline:
I had a significant vibration coming from 2 dying u-joints on both ends of my drive shaft, these were made even worse after lowering, and eventually created such a violent vibration that the only highway speed the car could comfortable drive without acting like a washing machine was nearly 80 mph.
If you have worn motor or transmission mounts, combined with worn suspension components in the rear, that could explain why the vibration dips in and out when turning as the suspension and driveline load up under throttle at highway speeds.
Aside from possibly the u-joints, I dont think this is your issue.
5. Anything that spins: Tires, wheels, rotors, the driveshaft itself, e.t.c. Make sure all this stuff is in good shape, and if possible make sure your wheels/tires are balanced properly.