.
...the only other suggestion I might be able to add to the above (especially in light of your filing two faces on a pin that requires only one), is that if you have the original profile from the ones that came out, and you have a bench ginder with a wheel big enough in diameter to have a flat side (and that is not terribly coarse in grade), certain less traditional mechanics have been known to very carefully and attentively shape the initial profile of the flat on the wheel's flat side. ou then finish it up with some light file dressing, which can be done as suggested by holding the file flat in a bench vise and moving the pin along it.

Someone will now come on and tell you why this is inadvisable, but it has worked numerous times for me, when I was too stupid to get the originals out undamaged.

Lately, I remove all cotter pins with that Bikesmith press, some 50/50 ATF-acetone as the penetrating oil, and a Mapp gas torch. I have yet to bend one since starting to do this. Maybe it's just coincidence. The heat and the penetrant really seem to help. Or maybe it's my belief system.
.