Wow, I've replaced many a ball joint and I've never had that problem. I'm thinking the hole in the second ball joint is just drilled wrong. Can you exchange it?
FWIW, if I had this issue, I'd buy another lower ball joint and compare it to the installed ball joint. If the hole in the new ball joint was drilled lower, I'd install that one, even if I couldn't exchange or get a refund for the other one. Considering how critical of a component a ball joint is, it's nothing to mess with. The price of a new ball joint is cheap insurance.
The LCA I bought from CJ had the same problem. I drilled a new hole to solve the problem. I plan on going with new Opentraker LCA with spherical bearings to take advantage of my adjustable strut rods for caster adjustment this spring
Father~Son restoration project
A code 66 coupe
289 4v, Roller Rockers, Electric fan
Performer & 650 Edelbrock
Tri Y into 2.25 Shelby side exhaust
T5 conversion and 3.55 Trac Lok
CSRP SN95 Discs
Castle nuts are available in both thin (short) like yours and in thick (tall) like you need. Take your short ones to an auto parts or fastener supply and tell them you need a tall one. If you can't find tall ones put a Grade 8 flat washer under the short ones.
I agree with awhtx. I just replaced all my '65's control arms, and the castle nuts are taller than the ones in your pictures. They are 5/8" tall in total, and 7/16" from the bottom of the nut to the bottom of the castellations. I took these measurements off the originals, and my new ones are the same dimensions.
The taper in the lower hole is not the same as the taper of the ball joint
stud. (They should be exactly the same however) - Quick & dirty answer.
If you were drilling a taper in the spindle and went too deep, that's the
situation you would get..... needing a washer under the castle nut so
that the cotter key slots would line up with the hole in the ball joint.
You can get the same effect with a factory taper on the spindle and
a narrow taper on the ball joint stud.
So, unless the lower hole in the spindle is badly wallowed out, that's
probably the scenario you're dealing with. Take a close look at the taper
of the lower ball joint.
ex-Global West GM
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