First off the alignment tool is not needed.
I first stated I used 12 but it was 14
The last ones I did were 12 and I did have to take them down to .094 as they are slightly fatter, there seems to be some confusion on these diameters.
When I first posted about using 12 It turned out to be 14 according to my wire strippers.
When I went to Home Depot and bought 12 it was in the area of .1019.
I shall look into this farther, I'm at work now and we have spools of wire and plenty of strippers so I can at least get an idea what's going on with the wire sizes.
I'm quite aware that the charts on the internet state the figures that you posted.
What I bought at Home Depot was 12 gauge non-insulated solid cooper wire, they may have made a mistake on the size but I don't think so.
So here is the wire I used to make the first pin, it's clearly marked 12 AWG on the insulation.
But when the insulation is removed it fits nicely into the stripper's 14 gauge spot and is smaller diameter than the clones original pin.
The non-insulated 12 that I bought is just slightly larger diameter than the original pin, perhaps it's measured with the insulation on in the case of the insulated wire but that makes no
sense to me but it certainly appears it's what was done.
On this link scroll to the chart and to 12 (in center, yellow)
http://www.dave-cushman.net/elect/wiregauge.html
Whatever the gauge I'm using ?? in the end my pins are .094
It looks like I maybe using BWG instead of AWG
And of coarse I'm using a micrometer for these figures.