could this be an issue with routing precision at the pcb fab?
I know from other fabs that you usually have to pay extra to get higher precision routing.
Some of the photos I’ve seen in the fix-my-six thread show some holes that have quite some drill offset, like for example here:
This leads me to believe you are using a cost-optimized fab. If they have a similar precision for routing, this could explain the problem and your footprint could be fine. So optimizing the footprint would be mostly about dealing with the exact routing tolerances of your fab and their process. In this case i’m not sure if it isn’t best done by an engineer of your pcb fab itself, because they know their process best.