Staking BB's In A Quick Release Pin

[billydng]

I’m working on an application similar to a quick release pin, where a plunger is depressed to allow a number of BB’s to fall within the O.D. of the body of the pin. This is not a quick release pin, but will be using the same concept. The BB diameter is 5/64”, and the O.D of the body is .250”. I can get the BB retained in the body, but have been encountering problems with the visual appeal. I have studied a number of quick release devices and have been trying to duplicate the results I see on them but have been coming up short.

What I have tried so far:
1. A hollow punch with the I.D. large enough to allow the BB to not get hit during the staking, and a radius on the end to match the O.D. of the body diameter. The thought was to try to stake around the entire circumference.
2. The same hollow punch, but with the sides cleared away and a flat surface so the contact is restrained to the crest of the part.
3. Next revision was a 10 degree angle on the face, which is looking a little better, but still not as good as the mass produced commercial Quick Release Pins I have.

Another question regarding the staking; we have designed the plunger to support the BB at the “locked” diameter during staking, the concept being that the staked material would flow around the BB to provide better retention. After staking though, the BB sometimes wants to stick in the outward position when the plunger is moved to the release position. I have tried applying some graphite based lube prior to staking with negligible results. Is it better to stake with the BB in the full released position? And if so, how is the stalking controlled to allow the BB to get to its full outward travel?
Any and all input would be appreciated. Thanks!