We've just received some PCBs back from fab, and there's a problem. The
boards have an PC motherboard-style power connector which is to take a
significant current (10A or so). The footprint will take either a
straight-through or a right-angle connector, and was prototyped with the
straight-through version which have flat pins. The holes are
plated-through, and the plating is electrically necessary.

We need to use right-angled versions. The only R/A connector available has
square pins. Our holes are the same diameter, but round. D'oh.

So how might I go about making a large number of square pins fit in round
holes? There's hundreds of pins to do, and a PCB respin is awkward. It's a
tight enough fit that simply hammering it in isn't going to be a great idea,
and filing the holes out is a no-no because of the plating. Filing the pins
with a flat file is going to be hard work (especially since they're quite
close together and can't be removed from the connector).

I did wonder about getting a die to cut a thread on the end of each pin (ie
make it round), but 1mm diameter dies don't seem to be easily available. Is
there something similar around?

Any other ideas?

Thanks
Theo