The first picture shows the washer electro blasted into place.  I used 4 tacks and let it cool.  I went on the the next mount, tacked it, and let it cool.  I was able to weld the entire front mount but, only able to weld about half of the rear mount washers due to space limitations.  I only did a little at a time.  I wanted to keep the mount as cool as possible. 

The next picture shows the completed weld.  Just remember with enough grinding anybody can be a great welder.  It may not be pretty but, I know there is good penetration and that's what counts. 

The last picture shows the A arm bolts.  The original and last year's version was black oxide.  The ones I just bought are now shiny.  To recap I used Polaris RZR bushings in the top and bottom arms, new bolts, new spacers, and new nuts.  The ball joints were good. 

Final thoughts:  After 2000 miles I can't complain about having to fix this.  It happens on Polaris, CFmoto, Can Am and, every other brand.  I always felt like I kept up on greasing these bushings.  I don't think it matters.  Some spacers came out looking like new and others were pitted and rusted.  Same story with the bushings.  One lower arm bolt had to be cut out because it was seized to the spacer.  The other side was bent.  Surprisingly the upper arm bushings, spacers and bolts were in good condition.  I wonder if the lowers fail because they are exposed to more water and mud?  That's enough of my rambling for now.

Great work! Good detective work finding those stepped washers too, that's just the fix I was imagining but not knowing the washers existed I'd have made them on the lathe, from round stock. What a time saver! I wouldn't even begrudge the $20.00 shipping.

[2015 Z Force 800 53/Trail EPS]

Nice work.

Very nice.  I found these washers also for those that need the washers .Not sure of shipping cost  https://www.hess-motorsports.com/products/weld-in-frame-repair-washer

This is what I like about this forum, great bunch of guys who provide clear descriptive information on various repairs, how to(s) and so on. It's very helpful an appreciated.  Thanks bezerk1!

[2015 Z Force 800 53/Trail EPS]

Yeah I think this is one of the best ways I've seen to fix and reinforce an egged-out mount..which seems to happen too often with these.

If it's OK with you Bezerk1, I would like to move this thread to the How-Tos.

Feel free to move it.  If you don't move it you lose it.

My nuts arrived today.  Girlfriend is very happy.  I ordered 10x1.50 which are not the correct nuts.  They are 10x1.25  I modified the post accordingly.  My alcohol soaked brain was confused once again.  10x1.25 will fit front and rear A arms, and shock mounts.  Sorry for the constafusion.

 You say your girlfriend is happy your nuts came in ... lucky you   

I finally got around to installing the poly lock nuts.  In addition to that I obtained some Nord Lock locking washers.  If you never heard of these lock washers check them out.  The first picture shows the poly lock nuts that I used.  I ordered a bag of 20.  Should be enough to last until the day I leave this planet.  Next picture shows the striations on the lock washer that grab on the frame and the head of the bolt.  The last picture shows how the two halves of the lock washer fit together.  Its hard to see but the angle on the ramps inside of the washers is steeper than the thread pitch.  The nut would have to overcome the pitch of the lock washer ramps to come loose.  Hard to explain so just watch the F'in video on youtube.  I do have to say that I talked to Nord Lock and their customer service is amazing.  They send me a sample starter pack.   We will see how they hold up to a little off road abuse.  All I have to do is touch up with a little super sleek black paint and this project is done.  I have oil, a filter, and gear oil to change for my winter maintenance.  I don't go by miles, I just change everything during the winter.  I might flush the radi tator too.  Just because.

Well that explains why I couldn't get the bushings out. I didn't realize they spot welded anything on the end. I couldn't tell what it was. I hit a big rock and busted the lower a-arm and it did a little damage to the mount that goes on the frame. It bent the mount a little bit so I thought that's why I was having a hard time getting the bushings out. I don't like how they spot welded them in there. I am sure they could have come up with a much better idea than that.