Yes I had the rod end shear off.  I am convinced that the geometry of the system is all wrong.  By this I mean that when you need the cylinder to completely close the door it is at a point where most of the pull from the cylinder is parallel to the door.  Also I feel that the cylinder should be to free to pivot about its mounting point.  This is due o the fact that the operating end moves in arc to close the door.  If the cylinder cannot pivot the force will impose a bending moment on the rod end and of course the rest of the system.

Ian,

 

The plans call for the actuator to vertically pivot at the cockpit floor attach point - indeed, the securing bolt is finished off with a castle nut so that it is loose enough to pivot.

 

I assume that the up-stop tubes were installed?  Note that although it appears the pull is parallel to the closed door, the door attachment provides a small arm about the hinge axis.

 

I have noticed many 320/360 inboard gear doors flapping horribly in the prop induced turbulence (especially if the doors are opened much beyond vertical) and I think that if the gear is dropped or flown above 120 Kts, this situation is worsened.  I wonder if such movement could work harden the rather small rod end?