Ok, so if I'm understanding you correctly, the problem is that the safety is too thin (well, not wide enough) at that point to allow for an adequately sized notch and still maintain enough material not to fail through repeated use. Is that the only problem, do you think? Because if it is, I agree with you that the answer would be a "wider" safety that would allow a good-sized notch (along with appropriate places for the user to place his trigger finger to engage/disengage the safety, since we're already doing a custom job, may as well do it right).The postion where the mag. follower BHO stops the bolt is so far forward, that your way up on the tip of the safty where the width is only ~1/4".
It might work well if you tooled up a uniquely shapes safety....but that's beyond me.
However, if the thing will still not work due to the problem I mentioned (bolt being held too far forward to properly catch and/or strip a round), it's all for naught.
Mike