Stick to it

Well, my fellow figure makers were right.  My experiment failed.  But I decided I'd better come up with a more reliable rod bending technique.  And here it is. 

I make sure the rod turns freely in the tube.  I make sure the rod is pulled forward to its maximum on the inside (I have bends on the interior sides of the rods where the spring will attach to the rods).   I hold a popsicle stick next to the rod and bend it over the stick.  The stick ensures there's enough distance between the bend and the tube to keep the rod turning freely. 

Only took 80 dummies to come up with this approach.  See how wonderful trial and error works.