Unirevolt-
I ended up tapping my spring pins through <img src="/forums/images/graemlins/shame.gif" alt="" />-lightly. It was'nt hard enough to do any damage to the threads though. If it seems like you'll have to REALLY drive them through, I suggest reaming out the hole (reaming bit) enough to get the pins through. If you don't own your own drill motor, (and it soundz like you don't) rather than paying someone else to do it, why not run down to your local hardware store, and pick up a rat-tail file, and ream the holes out yerself? At least that way you'll have a little more control over how much material You want to remove.
Tap the pins through, then put a little locktite on the threads and snug them down. You don't need to over-torque these as they can grenade on you, as you read previously. Also the pin is'nt really there to keep the pack together as much as it is to keep the leaves from shifting around in the pack. Tightening the U-Bolts will do that for you. Good luck Uni!! <img src="/forums/images/graemlins/coolg.gif" alt="" />