upnort16

I don't deny the pliers will cut the drill bit for shortening it for drilling reasons, but will most likely leave a burr or not flush cut. The drill chuck will go over the top with no ill effects, but pressing into a sized hole, or positioning a handle over it may require the end be ground smooth. One more point to consider, is the pliers themselves, the cutting itself could damage them and the piece coming off will be launched so catch it in a box or against something. Another method I've seen, but do not condone is to place the drill bit in a vice, smack it a good one with the hammer and it will break, or partially drill it into scrap and give the drill a twist and it will break off in the scrap. But given the use, a dremel is probably the most advantageous.

For small diameter wire, brass or roll pins would work for a while. Brass and roll pins are not near hard enough for producton though. Drill rod is an excellent choice, readily available, inexpensive and will most likely never wear or bend. Cutting a drill (high speed) is very hard, grinding or using a cut off tool is preferred. Dremel wheels work good, just mind the safety precautions! Epoxy will hold pins in if you cannot size the hole for a press fit. Good luck and keep us posted of the progress.