I had that happen to me the last time I did lower ball joints, ended up replacing the knuckle from a junk yard unit.

 

How much did your knuckle end up costing ya? I hear they are fairly pricey.

I was thinking of last resort, welding up the knuckle and tapping. That would be a lot of work. First the Knuckle should be removed but could be done on the truck. Then, I would have to clean and preheat the knuckle. Also making sure that I had some long cross hair lines to be able to find where the hole had to be again. Then weld and post heat, cover and slow cool. I believe the knuckle is cast steel.

Im really happy that the tapping caliper pin worked.