Did you try the new pin in the revolver as recieved to see if it would work?
That's the first thing I did. But the cylinder wouldn't close. The muzzle end of the pin wouldn't quite clear the frame and go into the channel. So I pulled the new pin back out and actually got out the digital calipers.
Also check the "hole" in the frame that the rounded end of the pin goes into. It might have been damaged as well.
I just went and looked at it with a magnifying glass. It looks OK to me. Maybe this is a case of good engineering. The pin is softer than the recoil shield, if the pin is slammed into that hole really hard, the pin dies but the hole survives?
Regarding your question: I would use a file to fit the center pin.
At first I was thinking about some little jeweler's saw or something but then I decided a file made more sense. So I think we are on the same page. Put the pin in a vice with wood jaw blocks on both sides. Only let a small amount of the pin protrude, file just a bit, take out and check, etc.
I was wondering about what profile I would leave the muzzle part of the rod. Factory rods I've looked at are basically square down there. Seems like just a bit of rounding would be worthwhile but maybe not?
I _think_ the cylinder end is the right length. Just holding the new one next to the old one, the distance from the little collar to the rounded end that sticks out of the star looks the same. I'll have to really, really examine it carefully before I take anything off the muzzle end.
Thanks,
Gregg