I just finished doing some very detailed measuring and came up with a few corrections and a surprise or two.
Regarding the short arbor assumptions we were all making (because Italian clones are all short right?) Although these were made in Italy, they were assembled and fitted in the US under whatever agreements were in place to produce the "Signature Series" Colt guns. I've always assumed my arbors would be like any other italian gun but they are both dead on. I'm sure someone could improve on them somehow but it would be well beyond me.
I took both guns removed the cylinders and put the barrels back on line up 90 degrees and set the barrels all the way down and even tapped on them with a mallet to be sure they were all the way down on the arbors. both guns bottomed out right at the frame with no bypass at all. I've read about measuring the short arbors this way but just never did it until this evening. So, I don't have short arbors it would seem.
On to the problem with the wedge - I found a surprise that may have just wasted a lot of time. My NEW wedge is narrower than the original wedge.
The original wedge fits perfectly fine. I replaced it only because it fell out twice and I din't want to loose it because it is a serial number part that matches the gun. I figured replacing it would take the pain out of losing one if it ever happened again.
The NEW ATI verified wedge is too dog-gone narrow for this gun.
I tried the same NEW wedge in my second Dragoon (also a Signature Series gun) and it doesn't go into the gun quite as far as the problem gun. But the notch on the spring is not against the frame as the original wedges are. So that tells me I do have some wear or deformation on the problem gun.
Shimming for the narrower wedges is probably going to be the simple fix.
Here are some pictures:
My New (edit)
Walker (edit) and my brace of Colt's Signature Series Dragoons with Kirst Konverters:
I took the NEW wedge and the original wedge and clamped them tight spring to spring (the only way to get them tightly together for comparison) and found the original was .02 thicker where it mattered.
Here is the original wedge installed. It is tapped in snug (I didn't set the gap just snugged it in for comparison):
Here is the NEW ATI wedge. If I tapped it in too hard it actually bottoms out:
So, what I've come to is that the new wedges are not correct no matter what ATI told me.
The original wedge fits perfectly but I still have a mystery as to why it wants to jump outta the gun (I'm suspecting the spring as a possibility).
The retention screw in the frame is a full round with no flats and in no way touches the wedge, it is there to snag the spring so the wedge doesn't have to be removed completely to remove the barrel. Tightening the screw does nothing more than make the screw tighter.
The shim idea will probably work fine with the new wedge. I'm going to try it. I need to go to the hardware store to pick up some copper shim material and see what I can cobble together.
This way, if I ever need to go back to the original wedges (like when I ever sell it) I can remove the shim and be fine.