Sac sizes: I just replaced the sac on a Sheaffer desk pen, and the sac I put in looks like it's a couple of sizes smaller than the one I took out; I decided to err on the side of not having the sac right up against the barrel wall (I used a 16, it looks like an 18 or 20 was in there before, unless it expanded as it hardened). The nipple on this one is pretty big; I had to stretch the end of the sac quite a bit to get it over. Is this normal?
Using knock-out blocks (removing nib and feed): Do most people use a hollow tube as a knock-out rod? I haven't removed any feed yet, but it seems that usually there's some fragile-looking part in the center of the back of the feed (exactly what varies from pen to pen) and I'd worry about damaging it if you tap it directly with a solid rod.
Removing sections: I have one Sheaffer that I cannot get apart; I'll try again with proper tools once I have decent section pliers (it wouldn't surprise me if that's the difference), but this one almost looks like the section and the barrel is one piece. If not, they're really close together; using a 10x loupe I can see what might... or might not... be a seam. Were any Sheaffer lever-fillers made as one piece? Seems unlikely I expect...
Assuming not, it may be glued together -- I've heard water and acetone proposed as solvents for superglue; other options? I'm a little leery of using acetone (though it might not matter if I end up breaking the pen anyway...).
Here's a picture of the Sheaffer:
