<<It might be better to keep the geometry closer to the factory unit
and make a new part with a larger nose for a pressed in bearing (if it would
fit inside the gear-tab..). That could perhaps give us the best of both
worlds.>>

This is the best idea I've heard yet.  (Although Bill Rumburg is probably
right -- snapping or bending the rod end bearing is probably a non-issue.)  
Still, the pressed-in bearing is elegant because it's just so much simpler,
and it can't be maladjusted.  I'll look at my gear this weekend and see what
I can figure out.  I also have a good CNC machine shop locally who I've been
talking to for work-related issues.  Since my airplane is upside down now it
would be easy for me to take the part over to show him and ask "how much to
make a few dozen?"

Anyone know what alloy it is?

So if there's room for expanding the end to accommodate a pressed-in bearing,
I'll draw something up, send it to the list, find out how many people want to
place an order, and ask the machinist for a quote.

Unless Tim or the Lancair factory wants to do it....

- Rob Wolf