The hammer appears to be correct although the slide/frame fit is not tight. So I can twist/move it a bit to one side or another when manually racking the slide.
The hole itself has some "flanging"(raised metal) from the previous beating the plunger tube and hammer gave it. It actually stopped the slide at one point. It doesn't appear the entire depth of the hole is that way, just the top edge. I used a 3/16" drill bit.
Some observations: The FP stop is loose. Not enough to fall out, but I can move it side to side and up and down a bit...very little but!
If I remove the FP stop and push down on the extractor keeping the plunger tube in, the hammer does not touch the plunger when racking. When I put the FP stop in, it raises the extractor slightly, lowers the plunger tube a tad, and then the the plunger and hammer can touch.
Perhaps the sloppy FP stop, extractor impacting each other a bit, after 35,000 rounds caused tolerance problems, i,e, not holding the plunger at the right level? Add a sloppy frame/slide to make it worse!
Colt already saw this gun about this and other issues. I won't bring up old and bad news, but they said it was within tolerance. Of course, it didn't work when they sent it back
.
Thanks