Front disc brake conversion on Demon-Now alignment is way off. Needing help!

1st, it would help if the OP would confirm if he actually has the 6272 or 6272A kit. As I read the product description for the 6272A (for the '72 and earlier models), the mfr provides a differently cast spindle to avoid changing to the later UCA for the disc brake setup. But if the 6272 kit is being used with the early ball joint, then it seems like the ball joint stud would not install correctly in the knuckle, as AJ suggested.

Some info seems to be missing. OP:
- Did the upper BJ studs snug into the new knuckle taper normally? (Can't tell from the pix..)
- Did you perchance change out the the upper control arms as part of this conversion?
- Is this the 6272 or 6272A kit??