The internal lug on the safety is what engages the sear, when the safety is "on". There is a very fine tolerance fit between the two pieces. Your new safety has the lug oversized slightly to allow fitting to the sear. Unless you are sure what you are doing, I would suggest having a smith look at it.
Generally, the safety lug is filed to match the contour of the sear. Do not file the sear. The fitting is done with the safety only. If you remove the mainspring housing and grip safety, you should have a better view of how the two pieces match internally.
As far as the safety sloppiness goes, I'm not sure how you can tell the two pieces don't fit togethter properly, if you can't even insert the safety because of the sear interference?
[This message has been edited by shane45-1911 (edited 08-28-2001).]
Generally, the safety lug is filed to match the contour of the sear. Do not file the sear. The fitting is done with the safety only. If you remove the mainspring housing and grip safety, you should have a better view of how the two pieces match internally.
As far as the safety sloppiness goes, I'm not sure how you can tell the two pieces don't fit togethter properly, if you can't even insert the safety because of the sear interference?
[This message has been edited by shane45-1911 (edited 08-28-2001).]