1936 G S/42 Very stiff safety lever
 

that can not be moved with just the thumb not just moving from the detents but along the entire arc of travel. Field stripped I can not see any rust or crud and all pivots points are oiled. I'm not comfortable disassembling any further and not going to try and bend the lever away from the frame as I understand it is brittle. Any thoughts on what is going on and how it might be corrected?

Thanks Eric

You are correct in not trying to bend the thumb safety lever. Doing so would surely break it.

The only thing to do is remove the pin securing the thumb safety lever in the frame and thoroughly cleaning the pin, safety lever, the frame recess for the safety lever and the sear safety. Before doing that make sure the seqr safety is not binding on the sear bar.

To remove the securing pin first remove the left grip. Then using a suitable small diameter drift, drive the pin down and out of the frame.

I broke off a safety lever just engaging it when I was a lot younger. It wasn't that tight, either.

You may need a smaller diameter retaining pin. TH

There are a few YouTube videos that show complete disassembly of Lugers. Watching once will show you how the pin is removed. It is not hard to remove or replace, and not hard to then remove the components. You do need an appropriately sized punch.

Thanks to all for your thoughts and suggestions. I disassembled the safety lever and bar by driving out the retaining pin and thoroughly cleaned everything but found little. Without the pin everything works smoothly but once its in it's as stiff as it was.

I think I'll just leave it alone.

Eric

The pin may be a little too long, causing it to bind in the slot in the lever.

Am I correct in understanding that it is the pin that retards the rotation of the safety lever by bearing against it? I measured the pin as 0.101 " dia and 0.518" long.

Thanks

The drawing gives pin dimensions aof 2.5mm diameter and 13mm long.
The pin actually holds the lever in its recess, and the spring tension of the arm in the detents also acts to position the lever; the pin does affect the rotation if too larger in diameter or too long.

I would try a little polishing of the diameter and see if it improves.

Like I said before if the pin is a little too long it gets very hard to move the safety.

You don't mention if the safety is matching or not; they are not "universal" and are fit to the frame- though usually pretty close to interchangeable.