An Old Bike Project is Never "Finished"

Looks like I spoke too soon. After riding the Runwell around a bit, it has developed a loud clunk in the right crank arm, the result of a mangled crank cotter that I just can't get tight enough anymore. Fortunately, I can order new cotters in the right size from Harris Cyclery, but it puts the bike out of commission for another week, at least, and forces me to confront yet another somewhat-dreaded DIY repair. I'd like to hear from anyone who has extracted/installed their own crank cotters without a cotter pin press. I've heard about bent pins, ruined cranks, etc., but I'd like to hear some happy stories with good endings. Anybody?