Oh, ouch. *wince* Poor Vic! Ok, how I modded my SAK.
First, I tested my technique on a junk SAK since I knew I didn't know what I was doing, and I very quickly found out that if you're going to do a full disassembly and remove all of the pins, you need to use a jig or vice to keep everything in place, otherwise all the parts go kablooey and you end up with a mess of parts and springs and spacers that looks something like
this except not as tidy. Ahem.
Second, I wisely decided that since I was only changing one tool, I really only needed to remove that one pin. I used a thin flat head screwdriver to pop the scales off, and then filed off the head off of the brass rod holding the little clip point blade in place. I used a punch to tap the pin down enough to slide the clip blade out and the nail file in, and then hammered in a new replacement length of brass rod which pushed the original rod the rest of the way out so it was never entirely without a pin.
Trimmed the brass rod to length and peened the ends, being careful not smoosh the little domes that stick up and provide an anchor for the scales. More trial and error and learning from mistakes here. Domes got smashed, pried back up, and dinged some more. Ditto the top liner. End result, the nail file doesn't have much snap but that's more to my lack of peening skill than the process itself and I'm not overly concerned about an unsnappy nail file.
The Vic models have a different pin set up so you either have to drill the pins out or file off the bushings and replace them, but then you don't have to worry about smashing parts that shouldn't be smashed when peening the ends of the brass rods.
Top is a Wenger model, bottom is a Victorinox just to show the difference.
Brass rod sizes are as follows (source: multitool.org forum)
Victorinox 58mm
-all 1/16"
Wenger 65mm
-all 1.5mm or 1/16"
Victorinox 84mm
-all pins 2.2mm
Wenger 85mm
-all pins 2.5mm
Victorinox 91mm
- 2 pins 2.2mm
- 2 pins 2.5mm
Victorinox Alox 93mm
- middle pin 2.5mm
- 2 pins 3.0mm
I'm not sure what size is needed for replacement bushings. ID same as OD of the pins, I'd think, but not sure of bushing OD aaaaand.... the battery in my calipers is dead so I can't measure one of mine. Sorry.
& That's prob more detail than necessary but I hope some of it helped.
(Edited to correct brass rod sizes for Vic 84mm and add Wenger 85mm.)