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Safety clicks off when the trigger is pulled and gun fires! What to fix?

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Hey Guys, I bought a refinished (reblued) USGI WWI COLT 1911. If you click the safety on and pull the trigger it shoots pulling the safety to the "fire" position. Obviously not a good thing.

Now I have a WWII Remington Rand 1919a1. If I take the safety out of that, and put it in, the safety works as it should.

That said I think the safety is original to the gun and I am pretty sure the sear is a replacement. Was there a difference in the 1911 vs 1911a1 sears? I am fairly sure the sear has been replaced as it does not have the age and wear to be original.

If I take the gun as is, there is a very small gap between the safety and the sear. If I put a eye glass repair kit screwdriver blade in that gap the safety works as it should. So it appears like the safety was over filed when fitting but I think its more likely that the sear was replaced and the replacement has less "meat" in this area.

The safety is blued to match the gun and replacing that would be the least best way of fixing this. If there is a sear with more "meat" in this safety interaction area that I could file to fit, that would be better. I know you normally file the safety to fit but...

If the sear is not the answer, I guess I could tig weld a bit onto the safety stud and reshape the interaction between the two but this seems a less desirable to me.

Any suggestions? I appreciate any help!
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A spot of TIG weld and refit the original safety. Or search for a period correct replacement and see if it functions correctly. The safety that fails the function test should NEVER be installed until repaired and re-fitted.
Joe
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A spot of TIG weld and refit the original safety. Or search for a period correct replacement and see if it functions correctly. The safety that fails the function test should NEVER be installed until repaired and re-fitted.
Joe
Joe, are you suggesting I tig the sear or the safety? I was thinking the safety would be better as I don't have to worry as much about the heat doing something bad to the sear. I can tig it pretty small but no matter how much, its still enough to melt metal at the point where it welds. On the other hand the sear has no bluing that I have to worry about screwing up.

I agree on the safety. It was not my doing. I am fixing someone else's issue here.
Tig up the safety and file it to where it functions properly.
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^^ This ^^
Joe
A dab of weld on the safety lug and a good bit of filing is the usual fix.
Probably what happened is the old sear was dressed a few times and the thumb safety filed accordingly. I am NOT suggesting shortening the sear…just what I have observed. As well other tolerance stacks enter the equation.
On your last picture. It maybe there but I can’t see a back cut on your sear. Sure got them well coated.
If the gun is reblued/refinished as you stated, then replace all worn parts with no regret. Your gun will lose no value, and you will rest easy knowing that the problem is fully addressed.
It's the thumb safety and the easiest thing to fix.
Another vote for tiging the safety where it was over filed.
Ok, guys, looks like Tigging it up is the way to go. I will try that. I should be able to get that to work. Thanks for the replies!

On your last picture. It maybe there but I can’t see a back cut on your sear. Sure got them well coated.
Yeah its got that back cut on the sear. Thanks, I usually take a gun down when I get it and oil it up well.
I tagged it yesterday and it works great now. Thanks for the advice!
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Good job. Lucky you hav TIG skill.
Joe
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