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getting ready to install poly bushings and noticed that I have 3 different cap sizes. Shouldn’t there be 2 of each size and not 3 different sized caps?
They all have different load placed upon them and some have the additional force with the camber bolts on the lower control arms. So not only have I noticed the caps vary but so too have the diameter of the pins on different kits.
I was lucky in that my new kit came with everything I needed. So I can't help you as far as reusing those because to be honest I was indelicate removing the factory bushings. I used a stepped bit to quickly ditch those caps and then a large drill bit to sink into the bushings themselves and make them quick and easy (a relative term) to punch out on the shop press at my friend's garage.
I have also suffered from project over runs or snowball effect. It went from slap an iron block donor in and be done, to fresh block, to I should forge it... And it kept on going.