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How about tapering the pin and the hole? This would reduce wear on them, especially in a case where the part was removed/replaced frequently. This might not be the case when used to align modules, but Iain Rice's book deals with stuff that could be removed much more frequently, such as "cassettes" (removable staging tracks), multiple layout "jigsaw puzzle" pieces, etc. These are kind of hard to describe in 50 words or less. I highly recommend his book, just to get the ol' brain cells stirring.
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