In My Experience...
I know this is an old thread, but it is a never ending question...
I have a Series 70 Combat Commander that I have carried for 24 years. About 20 years ago I had the gun, including the thumb safety, hard-chromed. That makes it a bit trickier to tweak.
After a hard 4 days of shooting and dry practice at Front Sight I noticed that the gun was failing the "click test" with just the slightest movement. I removed the safety and studied on it a bit. Since I'm planning to replace the safety regardless, I decided there would be no harm in doing a little experiment. I clamped the safety in a large bench vise with one hardened steel jaw against the surface that is 90 degrees out from the safety contact surface and squeezed. By squeezing the sides, I thought I could cause a slight bulging at the bearing surface and thereby solve the problem. After several trials and re-squeezes, torquing a little harder each time, the click went away.
There is no visible sign from the compression. The hard-chrome did not crack, and inking the surface shows that it is still making broad and even contact with the sear.
I'm no gunsmith and I'm not offering advice. This is just what I did and how it worked.
I still intend to replace the thumb-safety as soon as I find one with the angle and feel I'm looking for, but for the time being, I think I have made my pistol a little bit safer without a lot of headache.
By the way, someone asked the best way to depress the plunger spring for reinstalling the safety: I use a credit card.
With the gun lying on its right side in my left hand and the hammer cocked - double-check the chamber again - I drop the safety into place and apply just a slight pressure with my left thumb. Then I slip the credit card in under the safety from the back. As soon as the plunger is out of the way, the safety drops down and I keep pressure on it as I pull the card out. Works like a charm. If it's a current card, you want to be careful not to damage the mag strip.
Jeff