If you are going down the road of an all out 'new' build, I'm not sure if you missed it on the last page, but I highly recommend the KAD Tapered Washer over the stock split type. I'm 95% sure that the root cause of the issue you've found here is because of that split.
Thanks for your help and advice Moke Spider! I Really appreciate your time and knowledge. I can’t believe I was reusing those worn tapered washers all that time! The bearings were doomed from the start. I will definitely order new drive flanges and probably hubs too! I don’t want to do all this again for a long time!!
Cheers mate!
Your very welcome and thank you for your kind words. I hope it all comes back together OK and goes on to serve you well 
This forces me to wonder how many of the other "premature bearing failures" might, at least in part, come from the same cause?
As they say, the devil is in the detail. Like probably most of us here, for a good many years (long ago), I would just curse the failed bearing and change it without looking too much at the other parts, naively thinking that as they don't move against other parts, they can't wear, how wrong was I !!!!