Yeah I just read what I wrote. "lock" may have been a harsh word. Actually what I should have said was I snug My gibs. Although early on I may have done that one time and blew the pinion right out.
I'm hardly forcing anything though, but over time it does wear on the standard pinon just the same, and then the ocasional mishap. I Imagine the same could happen with the rack & a hardened pin as you say, but the little amount I'm talking about snugging them at is just enough to take away any chatter. There is a fine line there though, and easy to over do It. I can see It being one of the most common mistakes.

It does seem like it may be possible to blow one out from having the gibs too loose also. Wouldn't that let the pinion move off the rack alittle so the teeth only Hit on the tips at times?
I do ride that fine line though, and stay just under when turning shafts, but I make sure the ways have been scraped of glue, cleaned, and lubricated. Then I try to ajust them to get the most amount of play out without effecting the carraige from moving freely. That's pretty much the same thing I do when boring so I may have overstated that one. It definatly takes place over time with those, not the same as a mishap, and I guess like You say even that will wear on the rack over time. All I know is the lathe cuts alot better when I ajust them like that, so if it cost me a couple of pinions a year, then That's a small price to pay. Still though even on a larger metal lathe, that area in front of the chuck gets used the most, and that area usually shows the first signs of wear.
BTW, I like that last batch of toolpost bolts you sent. Those nuts that you replaced the stock ones with work much better. I haven't stripped one yet. I have one that feels like it's getting close, but it's still holding, and they seem to last atleast 4 times as long as the stock ones. That was a nice upgrade.
Keep up the good work