I posted on a previous thread that the kegerator I bought had a piece of PVC pipe used as a spacer. Since then, I installed two additional faucets and made the following observations:
In order to use 3/4" pvc pipe, you need a 1-1/8 hole in the door. You also need the PVC pipe to be cut at exactly the right length, otherwise the shank/faucet will always be loose or it wont function as designed.
I ended up sticking with a 1" hole in the fridge and snugging up the nut on the shank just enough that it wont deform the door and not move when pulling a pint. If I were to grab my faucets and twist, they would move, but why would I do that.
I should also mention that I didnt re-engineer the inside of the refrigerator door. Right now, my faucets run through the portion where eggs would be stored, and I have enough room to run a couple more through the butter tray if I desire (I do!). I also spaced my faucets pretty close together in order to maximize the amount of available space for more faucets.