Maybe should've titled this "My PT1911 Nightmare". I've got a PT1911 that I've been working up for the past year or so. Slowly getting around to installing some new guts in it. It hasn't had that many rounds through it, but some poor bubba attacked this thing with lord-knows-what-all. It was a problem-child and I got it for cheap as a project gun. This poor thing suffered from a super-light pull and the hammer would sometimes drop when the safety was flipped off. After getting inside it, I could see why. Attack of the dremel tool & crocus cloth...and the guy was a spring snipping fool too. Mainspring, action spring, plunger spring, about the only one he didn't get was the mag release spring! Luckily and surprisingly, he left the feed ramp alone! Long story kinda short...okay, not so kinda short... I noticed right away that the extended safety lever was tweaked in just a hair and rubbing on the plunger tube. Not a big deal, I was intending to replace the safety with a narrow extended anyway instead of the factory wide-extended. I was working on installing the new plunger/spring setup tonight and found that the new plungers wouldn't slide into the tube more than 1/4". Right about where the safety lever was rubbing the tube. Sure enough, you can see a slight dent inside the tube. What would you guys do to repair this? Find the right size number drill and pin-vise it through the tube to remove the displace metal? Attached are a few pics of the mess. The frame. Showing the nice bend in the safety lever. The plungers. Showing the exquisite dremel work (and Sharpie marker blue job!) in crafting the new rear pin. The new set is included for comparison. The safety itself. Showing the marks from the fine tools used to try to straighten out the lever.