Well, a little prodding from y'all; a little prodding from the folks I ride with; and a swift kick in the behind from, of all places, my boss to take the time as comp time and just go do it, I finally bit the bullet and made the pilgramage to the Waterford plant.
I went in terrified and more than just a little nervous; I left knowing that I had done the right thing. I have confidence that the new bike will be the right fit and the product well made.
The fit process was very analytical and not so much "does this feel right?" as much as "wrong angle, let's try this". A couple of times I sucked my breath as he made the adjustments thinking, "but it felt OK as it was". Each time, when he was done, sure enough, it was better. In the end the new bike will a little shorter in heigt and 5cm shorter in top tube length.
Egads...even though I knew the bike I had wasn't perfect, I thought it was close. But early in the visit it was clear they knew it wasn't. The guy that did the fitting, Dave, looked hard at my original bike and picked up on things like the fact that the saddle was pushed all the way forward and stem too short for the bike and knew it was wrong. When the owner walked in, he took one look at my bike; one look at me and said, "Way too big." Yep, these guys had clearly done more than a few custom bikes in their time. I rather liked the fact that they were able to say that yes, hat I'm getting is not standard geometry, but, also it is well within the expected. My guess is that if I'd gone with a bike shop that hadn't done enough custom fittings that I might have been way off their curve instead of "totally expected, just not stock sizing for any manufacturer".
When we were done we got to tour the factory. It isn't a big place, but a lot goes on in that space. Dave explained each step and the attention
to detail that they apply at each step. What became clear is that not just Dave, but the guys on the factory floor, seem proud of their product. To me, pride in product means it will be good. My confidence level has just zoomed up. I think I might have done the right thing!
Thanks, ladies, for kicking me along.