The purple "offset bushings" we include are indeed the correct size, the overall width of the assembled rod end/offset bushing combo is 58mm, identical to a factory upper or lower, front or rear position control arm's.
The arms / trucks we tested/ prototyped these on where my 05 TB and a local's 06 TBSS. All dimensions were identica amongst them.
So unless earlier and/or later trucks had some kind of change - these will work.
I didnt have these complaints until after we started including the boots.
I think alot of people are not "smooshing" the offset bushings into the rod end enough. The rubber rod end boots push them out a bit, but once a little force is applied, they squeeze down into them. We need this rubber seal to be tight or else moisture/dust/debris could be allowed to enter.
Here is a great comparison pic. On the left is the identical rod end with the identical offset bushings (the purple part) installed, but with the rubber boot (though the photo is of 5/8" rod ends, not the 3/4" you'll find on TB arms). On the right is no boot. Once you squeeze the nose of the offset bushings down into the rod ends cavity, it works perfect and provides an excellent seal.
I think a few people were excited to get them on and machined/ground down the offset bushings before realizing that it was the rubber boot holding up the progress.