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I was having problems getting the connector bars to go together without damaging the pins, but I didn't like the idea of making the pin smaller to fit more easily. Instead, I decided to put a 0.4mm chamfer on the edge of the pin, to guide it into the hole. For purposes of trying different things, I parameterised the connector bar and wrote it as an OpenSCAD file. I didn't include the fillet on the inside corners, as it doesn't really seem necessary, and I didn't feel like doing the math to include it :-)
This is one of my favourite fidget toys of all time, by the way