Don, Ed, you're both right.
Originally Posted by dnmilikan
Don, I think you left off a decimal place. A .0005 interference would be appropriate for a pin in the 1/4" range or smaller, which is about the size I imagine your registration pins to be.
Ed, you're right, a .005 interference would certainly bust things apart up to a certain size.
Old machinist thumbrule for press fits: .0005" for less than 1/2", .001" up about 1-1/2", then add .001 for every 1" larger. A .005 interference would be appropriate for a 5" diameter.
Caution: Thumbrules are known to vary from source to source.
Alex (Once trained in Wichita area shops)