Years ago I bought a replacement repro sideplate from Gun parts Corp. I ran into precisely the trouble that is being described.
After days of working with it I determined that it would literaly require machining to get it to fit. Too much trouble for what it was worth. I ended getting a period replacement side plate and it dropped right in.
The repros literally appear sand cast from a mold taken from an original. Far too out of spec to drop in with mere filling.
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