Bushveld,
Thank you very much for the advice.
The carpenter saw idea is perhaps even better since it would require even less finishing if I can find the proper thickness.
Indeed you are correct about the thickness of the tripper. Mine varies from .031" at the end which protrudes from the action knuckle, to .040" at the opposite end where the spring is located.
I already have a chain saw file which I use for removing material on the lumps when re-jointing but it may be too large a diameter...
Every bit of information brings me closer to a solution!
