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@Mc_Nebula
Ok, Cotters need to be fitted right.
I am led to believe that this is the way:
1) take your new cotter and press fit it, by hand. It SHOULDN'T fit. take it out, and file it until it does.
2) Refit the cotter. Bang it in. HARD.
3) Bang it out again...
4) Look for dark spots, where the pin has made contact with the axle (on the flat) file these back. you are aiming to get as much contact as possible.
5) having filed a little off, refit it, BANG IT IN, HARD
6) repeat the in, out, file until you have got a large-ish contact area.
7) fit one last time - Bang it in, screw the nut on tight, bang once more and do the nut right up.
This might not be 100%. People to check with include Murtle (hammer expert), Fruitbat and Skully