Gator_97 is my neighbor. I'm the one to be held responsible for introducing him to building AKs and the arfcom site. I've bent around 10 flats so far and had this problem on all but 2 of them. My initial thought was that my DPH jig was out of spec, but it measures exactly 1.25" and I've seen others post here on arfcom about the same problem. I feel that my flats are bent correcly due to the fact that the safety selector and trunions have fit perfectly on every one. The best fix I've seen so far here on arfcom is to "hammer around the axis pin holes on the right side of the receiver". This does work, but you guys have gotta understand that Gator's a "big time" NASCAR enginer and couldn't bring himself to beating the crap out his newly made AK. The e-clips that I bought here on arfcom fit the standard pins very sloppy, and allow the pins to move side to side inside the receiver. Gator's design lets the e-clip fit as intented on the pin, and its positioned slightly closer to the head of the pin making a tighter fit to the receiver. I've got a couple of the pins (prototypes) at home and they look really really nice. As soon as he has a larger batch made and heat treated, I'll have them in every AK that I've have built and some for the other 4 kits I still have laying around! I'll host some pics for him if he needs me to so you guys can see the quality of craftsmanship. I don't know how to express to you guys that this is not some backyard crap being pedeled here, these pins are being produced by some of the highest technological cnc equipment out there.
Gator, let me know if you want me to post some pics.