Model 41 warped frame, out of the box.

This may be the reason S&W has discontinued production of the 41. It appears they no longer have the personnel qualified to produce or repair the product.
 
So, they fixed it for free, the first time you sent it back, but you're through with them. Alrighty then.
While I'm not going to dump Smith...it has always puzzled me how these obvious QC issues are not detected during test firing etc...maybe they aren't fired?...maybe just given a cursory visual inspection, boxed and sent out?...I don't know, but some of the issues detailed by others here are so glaring, I can't understand how they would slip thru..?
 
I would suggest a complete field strip and re-assemble, taking care with the receiver alignment before locking into place, and if that doesn't work then a return to purchase source.
 
Some of the other comments make me wonder if the barrel tenon isn't machined properly and is throwing off the barrel and slide alignment on the OP's pistol. The lockup between the frame and barrel is critical to proper assembly of the pistol and operation. Or the cam that locks up with the barrel tenon could also be at fault. We just don't know at this point. In any event it really doesn't matter as it must go back to the factory.

I would give the Mothership a chance at correcting the issue before throwing the baby out with the bathwater. My new PC M-41 that I received a couple of days ago is perfect in all regards, not that it helps the OP. This morning I put another 150 almost flawless rounds thru the pistol of various makes being Eley, Lapua, Federal UM-22, CCI Standard and Green Tag. The only rounds that struggled operating the pistol were CCI Standard. Go figure. With my old eyes and shakiness at 10 yards it holds under an inch with Lapua and UM-22 and the factory open sights. I do better with an SRO, but don't have one yet for this pistol.

So what does my experience prove to the masses? Well nothing perhaps, or maybe a great deal. Contrary to popular discussion Smith and Wesson can actually build a decent pistol and one that really functions right out of the box. Even though I own another PC M-41 that needed immediate warranty work after purchase, for replacement of the slide lock assembly, this newest pistol needed nothing except a good cleaning and oiling. I can't recall the last time I fired so many rounds in such a short period of time with any pistol, but I wanted to prove THIS pistol could and would work as it should. I will add that I let one of the RSO's at the range I was at, shoot my new M-41 this morning and he was quite pleased with it. His immediate comment was, "Now THAT'S a pistol." I guess I can really put the return shipping supplies away for good on this pistol now.

I will forgo making anymore comments about the M-41 as it is quite clear Smith and Wesson has serious issues. How they can ship out one pistol that doesn't function at all and another one that works as it should is beyond me. Reminds me of another major firearm manufacturer having problems right now. At this point I have my M-52's to enjoy along with my two PC M-41's. There is simply nothing else in the Smith and Wesson stable that interests me. Of course I still have my department issued Model 66 with a department door shield stamped on the sideplate, but that is a cherished item and rarely shot.

Rick H.
 
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