Hi Bounty,
I just got two C&S pins today in the mail, they look perfectly formed to me.
I expect them to have to be fitted, I think that's the whole point in having them made extra long.
Maybe the "extended" C&S pins & the "undersized" current factory pins are all relative? Maybe by extended, C&S just means extended longer than current factory pins, not necessarily with more protrusion than the older hammer nose firing pins.
Possibly just a different way of saying the same thing you're saying.
I have two Smiths with MIM pins, the C&S pins are to replace them, so even if the length isn't a critical issue, or the mainspring tension, the choice of pin materials remains an important one for me.
Denis