That was how I determined the channel was undersized.
Detent would not drop in even when pushed on with a punch. (Use a hammer?)
The first rule in gunsmithing is modify the cheapest and easiest replaceable part so I smoothed the exterior of the detent pin with wet fine grit sandpaper. It still would not fit even when pushed on. (Just use a bigger hammer right?)
Pounding the detent pin through the channel is not the correct solution. The detent pin and spring have to able to move up and down slightly to disengage the slot in the safety for it to turn.
As I have other unused stripped lowers I verified the size of the channel using the smooth end of drill bit.
First I tried a undersize drill bit hoping to catch the offending material. No luck.
Courage, a couple of drops of oil and ran a the proper size drill bit slowly through the channel.
Obviously doing so removed some (most or all?) of the anodizing that was in the channel. So be it. I had a lower that was not usable. The channel for the safety detent spring and pin does not have direct contact wear points like the holes in the frame for the trigger, hammer pins and safety. Plus they are captured parts they are not going to fly off leaving the safety inoperable.
The result is the safety works smoothly and locks positively. If several 10's of thousands rounds from now the safety starts not to stay engaged when switched on or off I will replace the frame. In the meantime I have a fully functional safe gun to shoot and enjoy.