Torsion Bar clips won't install

The left side is fine, but with the right torsion bar fully seated in the lower control arm, the clip won't quite fit.

A little history. I completely rebuilt the front suspension on a 73 340 Duster project car. No problems were encountered, as this is my third. Then while looking for a donor car, I found a much better 73 Duster 6 cylinder car, and decided to build it instead of the V8 car. It would be a clone, but I would be a lot of money and time ahead.

The K-member on the V8 car turned out to have issues (it turned out to be bent, along with the front frame extensions) , so I modified the 6 cyl K member for the 340 motor mounts, installed the K-member back in the 6 Cyl car and bolted on the previously rebuilt V8 suspension. All went fine, until I put on the right torsion bar. (the left installed fine) The right bar is fully seated in the lower control arm. When you look at the back of the torsion bar it is beyond flush - it is almost to the point the clip will go in but not quite enough.

Since I have observed in past rebuilds that the torsion bar will go "deeper" into the rear socket as the suspension wears, I am guessing that because these are brand new bushings on the control arm that is the source of the problem. it is also possible that the machine shop didn't get them pressed completely on - and the problem didn't become apparent on the "other" car because of the bent K-member.

It looks like I am faced with two options, one of which is easier. I could disassemble the whole thing and take the lower control arm back for another run on the press. that might work and might not. Or I could spot weld two small beads on the back of the torsion bar to simulate the clip.

Any opinions (facts would be even better) on the cause the clip won't fit or suggestions on how to deal with it would be welcome.

Are you sure it was perfectly clean when installing the torsion bar? Is the grove that the ring snaps into clean? I wouldn't put spot welds there.....