Kill Dende to get rid of Earth's Dragonballs (to make this different from the OTHER times Piccolo's died), then have Piccolo die to whatever the new bad guy is, and in his final moments, have him spit out an egg to spawn a new Piccolo. Due to the rage at failing to protect Dende, or whatever, the remnants of DK Piccolo awaken and take over the egg so he's directly reborn, just in a young body. Once it hatches, have the new Piccolo hide it's evil intentions, and volunteer to be sent to New Namek to wish back Dende and everyone while the new threat is dealt with.
After the new threat's dealt with, cut away to Piccolo on Namek having fused with all the warrior Namekians on the planet, forcing them to accept the fusion or watch him destroy their villages. Given that just fusing with Nail put him on par with Frieza's Second Form, and Kami put him on par with Cell, that should make him orders of magnitude stronger.
Piccolo dying gives your Gohan the opportunity for some growth as a character, killing off Dende takes away your Deus Ex Machina with the Dragonballs, sure, but like this you can immediately get them back while Piccolo's on Namek, under the guise of doing as intended to maintain the charade. And while Gohan's dealing with whatever threat you're having him face, you've got Demon King Piccolo becoming Demon God Piccolo in the background unbeknownst to any of the Z-Fighters, so you can end on a cliffhanger to lead into the next Saga.
That help at all?
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