After watching the latest livestream, this problem has been haunting me for many builds, and I have some thoughts for feedback. Sorry for the length of the post.
After doing 10+ builds, I can say that I almost ALWAYS have less than 50% cruciform engagement on most of my builds. The question is why?
I always use OEM internal parts for the trigger housing, trigger bar, firing pin. Non-OEM parts are usually the connector, extractor, and sometimes safety plunger. Swapping out the internals has never totally fixed the problem, except once.
So, here's my current theory, which I haven't fully experimented on yet:
Probably 6 or 7 of my builds are using 80P Builder slides. Elite, Goon, El Jefe. I think it might be slide related, but not sure where. The reason I think this is because working on one of my builds, I swapped out the P80 rails for Rook rails and it actually made the engagement WORSE, and I have a sense that most of my cruciform issues are with these 80P builds. I've done some slide swapping before, but need to do it more methodically.
The other possibility is that it might be connector related, so I have some OEM connectors that I'm going to swap around and see if there's any difference.
And yes, as a last resort, I have bent the cruciform - a la Johnny Glock - to fix the problem because it was so bad and I wanted to experiment anyway. BTW - if you go too far, the gun won't fire.
The fact that Johnny Glock spent time explaining how to bend the cruciform tells my that he's seen it enough to know that there's just some cases when the tolerance stacking leaves no choice but to bend it. I mean, he's got a gazillion trigger bars to try out, but sometimes needs to bend one.
Thoughts?
I can see how a slide with too wide of rail cut could cause this or even rails that are too thin from sanding flat. Using Rook rails should help tighten the slide to frame up but you said it didn't help. It looks like it is a matter of swapping out part till you get a combo that works.
I wish I had more experience with gun smithing so I could help but this is a head scratcher for me. I haven't run into this problem in years.