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Super Moderator
EDC: SIG P938.
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The plunger should be short enough (that is, protrude little enough) that pressing the slide stop against it will cam it into the tube, and allow the slide stop to pass. If the pin protrudes too far, any pressure on it results in a bending force, and the plunger won't cam back. Shortening the plunger can be a fix, but it depends on the individual fit of the parts; if you just shorten the plunger enough so the slide stop can be pushed past it, there may be no spring pressure on it. It could also be the plunger tube is incorrectly located. You have to determine why the plunger is protruding too far into the slide stop window, before you start cutting on anything.
 

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Super Moderator
EDC: SIG P938.
Joined
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23,229 Posts
Excellent pics. The plungers cannot be swapped; the smaller-diameter one (for the slide stop) must go in the tube first. JMB thought of everything.
It does look like the slide stop is a bit too "tall", and is rubbing on the slide as it cycles. Kuhnhausen specifies the proper gap, at rest, but I don't have that one memorized; .015"? I assumed the "deformation" of the slide stop pin was a mold mark of some kind, as opposed to wear or damage caused by firing. Other than the circular mark on the bottom of the pin, the wear patterns look pretty normal, don't they?
 
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