Final update, with some interesting results.
I scrounged up a .495 S&W titanium fp, and an 11 lb rebound spring. Did a lot of testing today, with some very good and useful results.
First, my major error. Earlier on, I noted going to hammer shims. I figured getting all of the play out of the hammer would be good. Later in the thread, I noted having to go back up a little higher on the poundage, to get reliable ignition. When I was installing the new FP, I checked the hammer play. With the gun a bit dirty, the hammer was dragging a little when tested loose. I took out one of the 2 .002's on the left side of the hammer. I should have accounted for dirt tolerances when shimming.
Today, all DA, testing the s&w .495 firing pin and 11 lb rebound with an Apex firing pin spring (which feels lighter than the s&W stock spring) I was able to get down to 7.5 pounds before seeing an occasional light strike on winchester primers, seated in very mixed brass, seated on my Dillon. The high ones would go bang second time around. No issues with CCI's hand seated. And when I say mixed brass, talking Amerc junk and lots of mystery headstamps. With Winchester brass, Dillon seated winchester, no issues.
I then got creative. As my gun will correctly headspace and fire without moonclips, I tested a bunch of this mixed brass high primer stuff sans clips. Got down to below 7 pounds with no issues. I did not test lower, because 7 really felt bad to me. It felt "too light". Hard to explain, but that is what I felt. The 11 lb return is also right on the edge for me.
What this seems to be saying to me is that there is a relationship between the moon clips and trying to get really light. If below 7 works without clips, and it takes 7.5 or so with clips, there must be some loss with the firing pin having to move the clip mass forward in some situations. In trying to save some ammo today, I only tested TK clips, and nickel ones that I think are Wilson. I have a couple of other brands that are terrible with mixed brass. Probably worth trying some different brands if going really light.
I tested the Apex .495 and Apex spring earlier, and I think the stock S&W titanium is the way to go, if you can get a .495. Mine came stock at .490. Either going with the Apex spring, or perhaps a clipped s&W firing pin spring sure seemed to help.
I did not test out any of my AR brass today, but based on the behavior of the non-clipped mixed brass, thinking the AR should allow for some really light numbers. I am going to set mine up at 7.5 to 7 3/4 and call it a day. With the smoothed up internals and weight at this level, the gun feels stunningly wonderful, compared to the stock 12 lbs.
Thanks to Tom and the others here who have helped me so much.
Craig