[AM... do you have a first name?]
I was thinking about this on my way home tonight and, well, forget everything we've been talking about so far.... i think there's another issue here.
When I first saw the pictures you sent I thought your customer only had a daystar lift. I didn't realize he also had the OME HD coils for a "stacked" lift. His issue with the spindle rubbing the isolator with the stock arms is a product of his lift method that is avoided like the plague amongst XK/WK owners (same suspension btw). Kyle (oleblue27) can vouch for this... he tried a similar setup against mine and 07JeepXK's recommendation... and ended up ordering the 4" superlift within a month or so!
With that said, you solved your customers problem by moving the spindle further away from the strut, right? The problem here is that for the majority of properly lifted WK/XKs, your method of solving your customers problem is counter-productive to the design we need to get our alignment in spec.
Due to a lack of camber adjustment in the LCA, our aftermarket arms are designed to add some negative camber to help get our alignments within spec. Your arms effectively added some positive camber, correct? (because negative would have pulled the spindle into the strut)
Below is a picture of a stock arm and two pictures of aftermarket arms that members use that produce good alignment specs....
STOCk:
RRO:
JBA New Design:
Do you have another set of arms made already? I'll be tearing apart my suspension the weekend after Thanksgiving to replace a lower balljoint (the boot got torn). If you send me an arm and a return label I'll throw it on, take some measurements/pictures/etc and then send it back to you.