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I need to fit one of these to prevent any swivelling movement between a camera quick release plate and a tripod collar and am slightly uncertain about the size hole to drill.

I've bought 4mm pins with an uncompressed size of 4.4mm and can't see beyond drilling a 4mm hole.

The qr plate is aluminium and the collar is either also aluminium or possibly some sort of monkey metal.

It bothers me that it seems to be too simple.

From my experience you buy them to fit the hole size and they come slightly larger as you note here. Never had any trouble just drilling the standard size hole but I do find it good to chamfer the hole to help the pin get started. Aluminium can be troublesome though because it is soft and the pins are very hard. Take some time to smooth the edge of the roll pin to help it slide in smoothly, a tiny bit of wax or oil helps as well.

OK thanks, a 4mm hole, a touch on the hole with a Dremel and a wipe over the pin with some fine scratch and then some wax it is.

If that doesn't work. I'll use a bigger hammer.

Rather than hammering the pin in , can you use a clamp or vice to push it in , in a more controlled way , always assuming you can get a decent purchase at the rear of the hole.

Yes die-cast Ali and other alloy,s can be very weak in tension , think about ur Matchbox and Corgi cars

Oh I forgot another trick you can use. Pinch the roll pin in some mole grips/locking pliers, that will reduce the size to possibly even smaller than the hole allowing you to push it in with no effort, a compressed roll pin should be very slightly smaller than the hole it is intended to fit. This trick will only work on longer roll pins though where you have enough meat to actually get a grip and still put some in the hole.

I've got an ancient hand vice that I can give it a try with first, at 12mm it might be a bit short for mole grips, I do have plenty of hammers.

I always knew my 20 oz Estwing would come in useful one day, (apart from breaking toffee).