Observations:

With full down elevator (against the HS stop), the distance between the bottom of the idler arm/lead bobweight and the top of the rear elevator pushrod is 2.25" with the rod end bearings unthreaded as far as possible(no daylight in the holes). This seems high to me but I don't know anything so perhaps it is not significant. If the idler arm is too high at full down elevator, then I have made the rear pushrod too short...

With full up elevator,  I experience a binding condition (within about 1/4" of full up pushrod travel) where the rear rod end bearing of the forward pushrod attaches to the idler arm. Actually what is happening is that the fat part of the rod end bearing contacts the two idler arm halves and is no longer free to rotate as it should.

Seems to me I can do one of several things to solve this problem.
1. File away both sides of the rod end bearing to eliminate contact with the idler arms and allow the rod end to rotate on its bearing at full up elevator.
2. Remove the idler arm and file away material to allow the rod end to rotate at full up travel.
3. Make a new longer rear pushrod.
4. Place a washer as a spacer on the pivot bolt between the two idler arms and eliminate the binding condition this way. The downside here is that there will now be a gap between the two idler arms and the rod end bearings, requiring additional washers to be installed by a somewhat large person in a very confined space.

Slimming down the rod end bearing would be the simple solution but only if the bobweight is not positioned too high with full down elevator.

What say you all?

Angier Ames