So the gap is with the cheap bushes, or the super pro?
If super pro, which type did you get? the split type installed by hand, or the 20T press in type, like the original bush types?
if the issue is with the old cheap bushes, sounds more like that due to their cheapness, they weren't manufactured strictly to spec.
I haven't done radius arm bushes for a good 25+ years(back in my old RRC days) .. and I did plenty of them in the time I had the RRC, but never remember there being any gap of considerable note between bolt tube of the bush and the axle flanges.
Normally what'd happen is that because of the force applied to the nut/bolt, the flange would compress itself inwards anyhow, and always make getting the bush out harder than it should have been.
Using a washer tho .. not sure. Can't see why not, as long as it's a hard enough material. And you'd want to keep things centred and use one either side, rather than one only on one side.
How much gap between flange inner and bush tube?
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