GT,
I've seen a number of sear bars that had the sear nose/catch repaired.
They were spot welded and re-shaped.
Not much weld is needed, I suspect you know someone with a tig welder that could spot the nose of the sear catch. Then just work it down with a file.
If the weld is done with the right wire it will be sufficiently hard; if not just re-treat/case harden with Kasenite(Casenite?) and normalize.
However, if it costs much to do the weld or your time is valuable ; it is not worth it- except to save a matching number part. JMHO.
