The trouble with the FF Torsion bars...

Sub03

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That gap between the bushing and shell looks just like mine.
Not the FF setup on mine, I reused the hardware and ordered the bushings from polybushings.com

Pictures in this thread from a couple of years back, the guys also discussing a possible solution:
Torsion Bar Bushings
 

M_Body_Coupe

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...I have a related question/topic; I recently replaced my pivot cushion bushings with FF inserts/plates and NOS shells, and after putting weight on the car/driving a bit have a gap between the lower portion of the shell and the bushing. Your install looks like I would expect, bushings tight to the bars and shells. Is this typical or has anyone else run up against this?...
So here is what I noticed when I was shuffling through my t-bar parts 'basket' and trying to figure out the best set of components: the FFI supplied pivot bushing is correctly sized for the bar diameter they sell, that being 1.25".

In the meantime, the PolyBushings part# 1100 (polyurethane torsion bar MoPar) which I had previously purchased with the idea of replacing the factory rubber bushings (which had deteriorated pretty badly on my stock bars) is oversized. They say it is 1.25" ID, but visually when I compared the two side-by-side the FFI stuff was the smaller ID.
 
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