Burrs
Good point Graystar. possible, but not likely. If a burr was stopping the
sear from getting to the bottom of the hooks, it would probably result in
such a rough trigger pull that he would notice it right off the bat. There IS
a possibility that the sear nose is too short, or the sear pin hole is too
far from the hammer pin hole. If that's the case, the sear may be able to
bounce part-way out of contact with the hooks and jar off on the return to
battery.
But if the sear isn't contacting the hammer at all, could there be enough force in the hammer, as the slide gets out of the way, to fire the round?
Again...possible, but not very likely. The hammer riding the slide wouldn't
have a lot of "snap' behind it like it dies wen the sear gets tripped. If
the firing pin spring was providing nearly zero tension, or the firing pin
was too long, it would be a little more likely.
Hard to diagnose things like this without having the gun on the bench.
About all you can do is suggest the most likely causes and work your way
down.
The short sear theory has a lot of possibilities if the tip of the sear is
catching on the very tip of the hooks. It could easily jar off.
The last thing that occurs to me is that the bottom corner of the disconnector is protruding through the magwell a little. When that happens, the rims of the up-coming rounds can cause hammer follow.
Easy to diagnose with a flashlight or even by running a fingertip against
the inside of the magwell at the back. If you can see or feel that the corner is inside the magwell, that could be it.
Meanwhile, we wait for the gunsmith's report.
Tic tic tic...
Tuner