Mine came to me with the end of the spring inserted in the small hole in end of rod, instead of using a cotter pin. No small spring on mine, still looking for a suitable one. Also, I made a nice "grommet" out of 1/8" rubber, about 2"x2" with a 5/8" dia hole in it and slipped it around rod at pedal end and screwed it to floor board. Makes a nice fit, eliminates excess play at that end, stops rod from scraping against wood, and helps seal some of the hole which seems larger than necessary. Floor mat may also help reduce play.
Yes, I hear what you are saying. I was going to ask tonight about the hole size in the toe board. I measured (eyeballed) mine this afternoon and it is atleast 3/4" for a rod that is what, maybe 3/8" max.
I like your idea of the grommet. I was thinking about a nylon washer on the underside of the toe board.
Larry.