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Thanks for that, guess while I was lurking I should have read how to make a link hot
So, I did some measurements tonight and things look promising!
I measured on three different forged uppers, a Bushmaster made around '99 (my first AR,still got it), AeroPrecision that I bought a complete upper last year, and 3rd one I don't remember the brand.
In unaltered form there wasn't enough space to fit the rod between the upper and the bolt release, but it was VERY close and would require some clearancing. All three uppers measured at approximately 3mm thick under the bolt release so not a lot of material to play with. The rod itself measured just under 3mm.
Now the good news: I was measuring "about" 2mm between the upper and the bolt release. I say "about" because it was hard to get an accurate measurement with my micrometer based on the angle. One thing I did try was to stick the rod in between the upper and bolt release and cycle the bolt by hand. As it was the bolt felt like it was hitting the release but it didn't catch unless I held the release in farther.
At this point I'm feeling confident enough in my idea that I'm going to order a cheap upper to do some work on. Unfortunately I can't post pics to make everyone happy...