RE: 2/56 to 4/40 swap
The threaded one rods from Dubro and others have rolled threads on one end. The main body is a smaller diameter than the nominal thread size. If you try to thread the body, a die will leave jsut a trace amount of threads. SO, the ideal solution is to sloder a clevis on the unthreaded end and use your ball joint on the other.
I recently replaced the elevator pushrods on a 3d plane. They were 2-56 and I found that handleling and my table tie down were bending the rods. I went to carbon fiber and use the brass solder on thread extentions and epoxied them into the carbon fiber rod. This gave me a very stout pushrod, but the brass threads are very weak I found. They are more prone to bending that the orginal rods. I suspect my solution is going to be to solder a steel 2-56 thread into a brass tube that I can in turn epoxy into the carbon fiber.
Don