Fowler fixed at last. It took some deep sleuthing and the problem was right under my nose, as usual.
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In the above image you can see a tiny sliver of steel that's the top of the trigger, that's peeking into the sear bar hole. It couldn't drop down below the sear bar hole. This isn't a manufacturing defect, it's just a super tight tolerance that was minutely out of spec in drilling the hole for the trigger pin and/or a slightly larger trigger.
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The fix was to take off about .090" off the lower front of the trigger which allowed the trigger to drop down past the sear bar hole.
That's it, happy days are here again!
