I remember having a similar problem with the wishbone fitment on one side of the chassis, but I don't think it was quite as bad as shown on your photos. I overcame my problem with a hammer to belt it up into the bracket on the underside of the chassis. I don't know if that is possible in your case.
The best measurement I could take (not easy with the car on the ground) between the inner brackets was 19.5 cm. That is for wishbones based on re-using the E36 struts chopped down. If you've gone for the more modern setup Marlin were promoting a few years back, this may be different.
The only thing I can suggest for the ball joints is either there is weld splatter in the thread (which will not be easy to get out given the size of tap you'd need) or it's just the powder coat. Have you measured the thread pitch on the ball joint and in the threaded insert to see if they match?
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