I still have yet to see any “authoritative reference” as to how much allowance must be given for the fit since a true 1.0000” pin will not go into a true 1.0000” hole. My gut tells me the allowance should not be fixed (i.e. “always allow .0002”) but rather should be some percentage of the hole size (i.e. the pin must be .05% smaller than the hole size), but the function may not even be linear.
Generally, I think using gage pins for tight tolerance jobs is very poor practice. We had a vendor doing final acceptance testing on a part with a hole (~ .5” deep) that was supposed to be .6500”-.6503” with gage pins. My contention was that his method was unacceptable as it did not meet our required minimum four-to-one gage accuracy requirement. I cannot point to any “authoritative reference” to support that, but he admitted he could not tell me for sure how much smaller a gage pin had to be than the hole size for the pin to go in.
And, how much force is acceptable to be applied to the pin to get it to “go”? Any authoritative references on that?
Generally, I think using gage pins for tight tolerance jobs is very poor practice. We had a vendor doing final acceptance testing on a part with a hole (~ .5” deep) that was supposed to be .6500”-.6503” with gage pins. My contention was that his method was unacceptable as it did not meet our required minimum four-to-one gage accuracy requirement. I cannot point to any “authoritative reference” to support that, but he admitted he could not tell me for sure how much smaller a gage pin had to be than the hole size for the pin to go in.
And, how much force is acceptable to be applied to the pin to get it to “go”? Any authoritative references on that?
. The standards discuss various methods of gage tolerancing available to use given specific product application parameters. You should pick-up a copies of: 
The current gage practice (in USA and EU) is: The GO plug gage is made at the low limit of the product tolerance with the gage tolerance all in the plus direction. The NOGO plug gage is made at the high limit of the product tolerance with the gage tolerance all in the minus direction. There is not an allowance between the gage and the product. If you start applying an allowance then you will get the same situation as Caster reports.
The good part is that after you have read the standards you will be able to say to your boss, or to anybody else questioning your policy, that it is supported by [insert standard number with paragraph number here]. That will usually shut them up and you can go on your way. If not, you can ask them to show you 