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AR15.COM
5/9/2007 3:24:58 AM EDT
I'm having problems with my thumb safety partialy engaging while shooting a course of fire. At least that's what I'm assuming. During a course of fire the dang thing just quits shooting, I look it over and the gun seems to be in battery. I rack another round in the gun and continue shooting. While practicing the other day it did it again. I took the time and looked it over real good, sure enough the thumb safety was engaged just enough to stop the pistol from shooting. I never heard of the plunger spring wearing out. If so should I replace the safety plunger along with the spring? What about the slide lock plunger? Should I replace everything as an assembly?      
5/9/2007 6:34:58 AM EDT
[#1]
The plungers typically don't need replacement unless they are noticeably worn.  I have had to replace the springs from time to time in different guns as they wear out.  Some folks have also been known to cut coils off the spring to get an easier engagement.

Replacing the spring is the easy fix.  If that doesn't do it, you might be looking at having to deepen the detent in the thumb safety itself.
5/9/2007 6:52:51 AM EDT
[#2]
+1 on on Ken's suggestion about the detente. I had the same problem on one I built. After contouring a Wilson thumb safety that wouldn't clear the plunger tube, I spot drilled the detente and problem solved. Might as well check and deal with both while you have the safety out.

Rick