Hmm, I think I have found the problem (but I've said that before).
I decided to simplify things, disassembled the gun, and while it was apart, I just put the slide on the frame, but this time with the magazine in the gun. No barrel, no recoil spring, just the slide, barrel, and magazine.
I moved the slide to the rear, then moved it back and forth. As I did so, the safety started to turn on!!! This is without my touching it. It's very repeatable, but without a third hand, I don't see how I can. capture a video. Will try some more..... Check the area by the hammer, to see how little I've moved the slide!
Here are two photos, one with the slide back, and another with the slide pushed a little forwards.
With the magazine in place, the firing pin and spring assembly "binds up" like something rubbing. I'm beginning to think what is rubbing is the safety rubbing on the firing pin somehow.
This may explain why the previous person to work on the gun said he was filing a "burr" off from the safety. Maybe the safety is defective? Maybe this other fellow damaged it? I have a new safety on the way, so maybe that will be all it takes to fix this.
I need to load more ammo, but if this is what's going on, if I push the safety towards the "off" direction, the gun should fire, and if I keep checking it, I expect I might find that the safety is turned partially "on" without my touching it.
Regardless, nothing that I'm aware of, that I'm doing, should be activating the safety. Bizarre.
Don????
(Oh, I tried pushing on the plunger from the bottom of the slide - it moved roughly, not smoothly, but it wasn't obviously stuck, and I don't see how it could possibly be in there twisted, not enough room.)
Added later... With slide on frame, pressing on firing in, it moves very smoothly. Without changing anything else, I insert a magazine, and press on firing pin, and it's either very rough, or bound up. So if I put in the new spring, plunger, and safety, maybe one of those will eliminate the problem. Sounds reasonable to me.