There is an alignment issue with brazing it. That would be too easy. I did find a "fix" used by Ken Jerrems in Australia and this is a link to that information: http://alasdair.muckart.net/files/KenJerrems29k13/EngineeringDrawings/SINGERTENSIONLIFTRODMODS2.pdf
I am going to try that. I do have a metal lathe and milling machine, so this is feasible. The alignment issue is that there is a "fin" on the bar the slides in a groove in the head and the arm must be perfectly positioned to correctly work the tension release. The threaded stud method allows the arm to be rotated to get the correct alignment. I think I will have to machine off a bit of the rod and put a flat washer on both sides of the arm to overcome the wear on the end of the arm.
Thank you for the suggestions.
BTW, I did replace the check lever spring and that did help with the birdnesting, but I think the tension lifter will also help in creating the correct stitch.
Peter