[blaiz]

One side of the pin should be hallow. If you have access to a ball point hammer these are ideal. Place the pin throught the flopper and shaft and carefully flare out the other side until its flat. You dont want to work on it too much as it will weaken the pin.

be sure to have something solid behind your shaft when you start hitting the pin (i.e. steal plate, flate part of a bench vise, or smooth cement)

On your existing flopper you might try opening it up a little with pliers before you take it off.