I had the opportunity to measure a new lower's bolt catch pin holes. As best as I can tell this units holes are .088-.089". A number of 3/32" pins measured .092" measured from the split side to the opposite side, and about .098" on the non split sides. Once I squeezed the pin shut and measured again, it was about .092"
In a fastener manual I have it shows a 3/32" pin as being a max. .0938" and min. .0928"
Recommended hole size is max. .0956" and min. .0938"
I think a combination of undersized holes and a lack of "meat" on these ears are a big contributor to causing these to split.
I measured a number of 3/32" pins from different sources and they were all virtually the same, including one from a new DPMS LPK.
It's not to big of a deal to emery a pin down, if you know ahead of time that it needs to be done.
Hope this helps.