Hi Mauser,
You hit the nail on the head. Some of the issues result from spotty QC and materials. The over travel of the flintcock is a design issue. Look closely at the photo I posted above. Behind the flintcock on the stock of the wood, you can see the little dent created by the flintcock pulling back too far beyond full cock. No one can ever accuse me of leaving too much wood on stocks around locks and the only way I could resolve the problem was grinding and reshaping the bend of the flintcock so it cleared the wood if I pulled it back to where it is stopped by the lock tumbler. Davis replaced the flintcock but I just ground off the cracked and broken bolster at the rear lock bolt hole because the thick plate had plenty of threads to hold the screw and I had reshaped the plate and inlet it. I would have had to reshape a new plate exactly the same to fit the mortice and the old one still works. I have a replacement plate ready to be shaped if I have problems in the future. I also do not like that they use small 6-40 screws for the internals despite the size of the lock and parts. They could easily fit stronger 8-40 screws. It seems Davis uses 6-40s in all of their locks so it is a cost cutting measure.
dave