Originally Posted by
63rickert
Bikesmith tool shoved a big gall of metal up the wedge face of pin. Not even going to try to figure that out.
This sounds like the angle of the flat may have been too steep. Are you filing both drive side and non drive side pins the same amount and at as close to the same angle as possible?
Filing cotters is tricky indeed. Are these the originals, or are the ones that were installed initially still around? If you have one that previously worked intact, then you have a reference point.