John Browning specified a 5/64 radius, so 5/32 drill bit is a match. I use EGW stainless ones. You have to fit the width
and the thickness of the two side rails, and then clear the top and rt side of the ejector(left side of notch in FP stop) , and finally,
once it is sitting in place, located by the FP, trim off the bottom to be flush with the slide. About 1/2 hour with a couple of fine cut files. EGW
comes with about a 1/16th inch radius or less on the bottom corner, but you should wait to do the radius until finally fitted.
Leave it JUST clear on the sides to hold the extractor snugly. Less critical front to back, but easy enough to leave it at .001
to .002 clearance. I mark with Sharpie and tap it in, then file where the Sharpie is wiped off.
I made the one in my carry Commander myself on the mill from bar, for fun and because I couldn't locate a SS one at that time.
I'm not sure would leave the radius like Brad has, but I am also not really sure if it will harm anything. It will hold the
slide forward harder, since the mech adv is even less favorable with a near zero radius. Testing will tell. I tend to
refer back to JB's original ideas and stay there, other than ergonomics. I have both Kuhnhausen's books and the original
GI blueprints and do refer to both. One of my best books is a little self published one from a guy that I met from
OK, used to see him at gunshows for decades, but his health was failing about 10 yrs ago and when we last spoke he
said he was about to quit the gunshow circuit. He had been an AF match armorer on 1911s and had put down all the
basic, old-school working techniques. Some things are dated, now that we can get wonderfully high quality new parts,
but much is still valuable knowledge. Long out of print, not sure if he is still around, either. Nice guy, perfectly willing
to explain anything if you asked.
Bill