What are your 2 cars you are fitting '34 brakes to? (I'm new - so there are no obvious reasons.)
I am also of the opinion that many of the replacement roller pin heads don't have enough surface area to properly ride on the roller track. Too much radius/chamfer on both sides of the pin head and not enough 'flat'. I've yet to figure out how much of the head is riding on the flat track to know if it is a problem or not.
Cotterpin hole & stackup - If rollers are 0.25" thick each and the meat of the shoe the pin goes thru is 0.25" thick how far from the head of the pin do you plan to put your cotter pin hole's edge? (i'm sure shoe thickness varies more across parts than the roller thickness does) I would think some play between all the components is prudent, just don't know how much - although the drawing does have a min max dimension to the center of the cotter pin hole from the head.
Do you have a target rockwell for your surface hardening?
But I am very curious - how to avoid rust? I believe current pins are plated for that avoidance.