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I have had the exact problem with one of my frames. I too have 3 other 1911s of which i built 2 myself. I have changed everything on that particular reciever. I have even swapped parts with another and had the same result.
I have to agree that the reciever is out of spec due to a previous owner or wanna be gunsmith trying his hand.
The only solution i can think of in my case would be to have the thumb safety welded so that it is way to big and file down bit by bit until it sits tight and allows no movement on the sear?
The amount of movement i get on the sear with thumb safety engaged is worrying.
The weird thing is i just logged on to ask what i should do and saw that im not alone.
I too would like to fix this. I have fired this gun a few times and it does not double. It fires normally. I do keep it disassembled though for safety reasons
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