That kind of casual measurement and style of mfg might be OK for a highly diffused masking setup, but would be highly questionable for precision tricolor work. But in this case, you might get lucky and land with something standardized to begin with. Yupo isn't dimensionally stable, so I don't get that. Good luck with your project.
ACT (American Circuit Technology) still offers oval as well as round pins and tabs. The new frontier of film registration
involves printed circuits; but they also supply pins to the graphics and arts trades. They can also custom manufacture offset step pins like Condit used, but that would probably require a high-volume group order to make it realistic. I wouldn't mind having half a dozen spare pins on hand, but not 6,000.
I discovered that later versions of Condit had more consistent micro pins about .002 inch smaller than the earlier ones
which were machined out of 1/16" dia brass stock. Stainless micro-dowel pins are readily available in both 1/16th diameter and a slightly different metric diameter, but not with the convenient offset stepped feature which is the most desirable. Still, by drilling your registration bar holes just a tiny bit bigger diameter, you can precisely epoxy your pins in if a pre-punched sheet of dimensionally stable film or shim stock is on hand as the exact positioning template. Never use "10-minute" epoxy; only the overnight thin liquid type.
Another trick would be to cannibalize used registration strips, which are abundant under graphics and printing industry listings, along with used punches.
It appears that Ternes Burton is down to a one man operation nearing retirement, with more limited options than before.