Rock Shox mounting hardware – what’s going on here?

I’m trying to fit new IGUS bushings and mounting hardware to a 2022 Rock Shox SIDluxe rear shock. Previously using the standard RS metal DU bushings and aluminium hardware, which worked fine.

I can install the IGUS bushings without issue using a bushing installation tool. But when I try to push the mounting hardware (pin) through its super tight and ends up just pushing the bushing out the other side e.g.

I’ve tried using the Rock Shox bushing removal tool (which also doubles up as a hardware / pin fitter and remover), sticking it in a vise, pushing down against the pin on the edge of the workbench using sockets etc and always the pin goes in a bit but then the bushing gets pushed out the other side.

Both IGUS bushings fitted to isopropyl-cleaned, non-lubed eyelets.

I stuck the pins in the freezer overnight and doing this I managed to fit them with great effort, without the bushings being pushed out, but then they just bind to the bushing and the bushing rotates in the eyelet, rather than the pin rotating in the bushing.

Using digital calipers, the eyelets of the shock measure up 14.9mm, and the pins 12.73mm, so I am guessing this is some sort of tolerance issue?

Anyone else had issues using these types of bushings in RS shocks?

Sand the inside of the bushing down a bit. Had to do that on bushings for a few shocks. If the mounting hardware is too tight it wont rotate in the bushing so will just wear the frame.

I’ve had this issue before, using a grey poly bush instead worked or maybe using the original rockshox black alloy pin is an option, I’ve done both, the combo of the igus and steel pin is too tight on Rockshox shocks.

Thanks for the replies. Yeah I am going to see if it fits with the original RS alloy pins (currently fitted to the bike with a different shock). Failing that will just have to buy a couple of different kits.