Not sure if this has been performed or posted. I'm not even sure it's the safest thing out there, but it worked for me. When my brake pad pin broke off while trying to do a routine pad replacement, I drilled the damaged threads out and installed a cotter pin. After doing this I looked at my girlfriend's Shimano brakes and low and behold they use a cotter pin also!
No problem doing that, the only drawback I see is that if it isn't "tight", it may make some noise while riding ...
It just voided any warranty you may still have
Yep, almost the exact size as the pin so we're good there. I guess not missing a day of riding is sometimes more important than the warranty on small parts!!