I replaced mine last fall. Got two boot kits from the Bus Boys that had
everything, even new washers.  I also got two CV and boot kits from the Bus
Depot (after taking everything appart and seing some wear and heat blueing
on the two inner joints), those kits did not come with new washers and
looked a little different than the Bus Boys, but still looked good. Because
the boots appeared a little different than the OE ones, and I could not
just position them at the same location on the axle shaft, I greased the
shaft where the boots sits so that they could slide "easily" and drove my
Westy for a week to try and get them to position themselves properly before
putting zip ties to seal the boots to the axle.  BTW I used marine fuel
line zip ties as they are made specifically for round object and therefore
have no flat spots.  Because of your experience I will keep an extra eye on
mine, but maybe you streached your boots out a little too far when you
sealed them to the axle?  Just a thought.

Pascal
'84 Westy