Lower Control Arm Doesnt go back in????

One piece strut rod bushings were available a few years back from ESPO (Springs and Things).

Also Spicer Pro and Moog Professional series had an improved rubber strut rod bushing that is supposed to really last.

When I rebuilt my 1969 340 Swinger in 2000, I used all rubber Moog Pro bushings, with poly only used on the factory sway bar. Everything went together the first time with no issues.

Sorry to hear about the issues with your front end build.

Over on Moparts, there was a thread a few years ago about this very issue with the poly bushings in the LCA and the strut rods. The final verdict was stick with the improved rubber bushings from either Spicer or Moog, but use poly bushings on the factory sway bar.