Do this bevelling manually? after doing the extrude just use the split polygon tool to add your bevel by hand along the existing loops only. Its alot more waistfull on the poly count but it will work better with smoothing (perhaps dont smooth?).
Though to be honest with small bevels like this you can just use a normal bending shader, mental ray has one and it works nicely. I think its called mia_roundcorners.
FX supervisor - double negative