Cotter pin removal. Any tips?

Simple way.

Old seat post or similar tube cut to length.

Block of wood on floor, tube up to the crank. The idea being to transfer the impacts direct to the floor through the crank rather than stuffing your bearings.

For the actual hammering it's a good idea to use 2 hammers. A nice heavy ball peen or similar resting on the cotter, and whack down on this. That prevents damaging the crank by misses.

Big whacks rather than delicate taps are the way, and better if it's done with intent.

(I've been doing it this way for many years)
 
Also, to save the threads, leave the nut on!! Just loosen it a turn or so.
I'm not suggesting saving the pin for reuse, but as others have found, if the threaded end is used for taking the hammer blows alone it will distort. Leave the nut on and it will stay straight and true.
 
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