Re: 1911 Thumb Safety
Pull the safety. Remove the plunger. Put the safety back in. Try it. Still stiff? Plunger wasn't the problem. Works real easy? Looks like it was the plunger/safety interface.
Look at the face of the safety. Is there a burr that might be catching on the plunger? Look at the face of the plunger. Is there a burr that might be catching on the safety?
If it turns out that it is the plunger/safety interface, and there are no burrs on either piece, I'd still do like Country suggested and work it for a while and see if it wears in.
I like a very distinct "on/off" with mine. My Kimber's safety is so easy that if I lay it in the glove box, with the safety on, just the motion of driving a few miles will take the safety off. That's not good.
Meddle not in the affairs of dragons, for thou art crunchy, and taste good with catsup - George of Lod, Year of Our Lord 297
I always take precautions.
Beware the Evil Bullet Fairies.