The Powerflex bushes for the engine stay bar are a VERY tight fit and IMHO are meant to be to fill the gap between the outer housing and the inner bush through which the mounting bolt fits.
When I had a set (which Dave S now has) there was no way I could force theminto the gap by hand. I think it requires the pressure from tightening the whole thing up to force the Powerflex into the gap. This will then provide the required stiffness to the whole bush.
Somehow what you have done does not sound correct.
Have a look here: http://forums.t5d5.org/topic/4575-po..._hl__powerflex
Personally I preferred the cheaper repair washer trick to make the whole stay bar solid.
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