This was also posted to the samba, here:
http://www.thesamba.com/vw/forum/viewtopic.php?t=458028

Figuring that anything I run across has to have happened many times to others, anyone have this problem?

The lower ball joint is pressed into the spindle, looks well-seated, and clipped in at the bottom.

The tapered shaft though, doesn't come even close to reaching it's shoulder.

I've already ordered another lower ball joint, and will test fit this one to the lower arm before having it pressed into the spindle, but it seems strange if the manufacturing specs could be that far off between units.