> Doesn't seem that the old spline groves help with
> this either.
Might be time to try a trial assembly off of the car, with just the front
arm & no spacer. Perhaps that will show you where the problem is. Kind of
sounds like perhaps your new ball joint is not properly made.
Using a press is going to be tricky, as the sides of the ball joint housing
are not at right angles to the shaft. You could possibly use a (stronger)
standard nut in place of the thin castellated one, but finding one at your
local hardware store might be difficult. ISTR those are something like 9/16
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