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For some reason the durn tie rod just seems too big. I put 71 disk brakes on my 67, and all the ball joints line up fine, but the tie rods just seem too big. I orderd the 71 tie rod, not the 67, so thats not the problem. The 67 one i tried for kicks seems too small.

I got them from american pony / canadian mustang so im fairly sure its the correct part.

Also i checked the spindle and it has D1 stamped in it.

I cleaned out all the paint from inside the tapered hole and from under the nut area.

I can get enough to get the nut on and barely see the top of the cotter pin hole, but i cant even get close to tightening them down enough to get the cotter pin in.

Any ideas?
 
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