Two suggestions -- you might want to try a blended polymerase preparation, like Invitrogen's Platinum PCR SuperMix High Fidelity (Cat. No. 12532-016). This is a mix of Taq DNA polymerase and the proofreading Pyrococcus species GB-D polymerase, and provides ~6X higher fidelity than Taq alone (see
here). Additionally, the majority of fragments amplified with this mix have a 3-A' overhangs, so you wouldn't have to try and add them. And, because it's a supermix, there's less pipetting involved -- the mix already contains dNTPs, Mg++, etc.
I don't work for Invitrogen, I've just used this product for years with good results.
To protect your DNA during gel purification, add 0.28 g/L (~1 mM) guanosine (e.g.
Sigma G6752, FW 283.24) as a UV protectant to 1× TAE and stir with gentle heat until dissolved. Use this "sunblocked TAE" to cast the gel and as running buffer during electrophoresis -- see Grundemann, D. and E. Schomig. 1996. Protection of DNA during preparative agarose gel electrophoresis against damage induced by ultraviolet light. BioTechniques 21:898-903.
pdf here.