I finally got around to building the tab tool and used it to install new OEM tabs on my 1991 240 sedan. Photos are here:

http://www.flickr.com/photos/jetstar5224/sets/72157622512917998/

To the person or persons that devised the concept of this tool, thank you and a tip of the hat to you! I also appreciate all of the helpful advice I received regarding installation orientation of the bushings, the taper, etc.

The only thing that I wasn't expecting were the welds on the original (I think) bushings, retaining them to the axle eye brackets. As far as I know, the rear tabs had never been replaced (if the condition of rest of the car's parts are any indication), so I was surprised to see how much weld had been placed there, to the point I would have been concerned that some of the rubber would have been damaged. I didn't tack the new ones in (although I do have a small MIG machine), and I have seen other makes tack some bushings in (ala VW Vanagon). I guess I will keep an eye on them for now, but I sure can't see them shifting in their positions.

Anyway, I hope the photos help someone contemplating doing this job, and again, thanks everyone!

Dave Milo