we always used a G clamp and a 10mm socket (7/8" will do too) to give give head room for the pin to stick through. getting the whole frame on the bench to push a pin home with a bench vice was always a pain in the neck.
Had a cotter pin shear once, on my Harry Quinn track bike. The left crank came completely adrift during a Nottingham Track League night. Probably due to an excess of hammering it in and damaging the thread.
Being a daft 14 year old lad, I tried to ride it back from the track down a slope to the car park, lost control and only stopped when I got to some railings.
First person to arrive and check if I was OK was Beryl Burton!
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