I didn't mean to be sarcastic about this, I just wish you would have given me a call right from the start. I could have suggested some things to try because, being the maker of the lock, I think I would have been in a better position to analyze the problem. Being sarcastic again, I wouldn't take my Ford truck to a Mercades dealer to have it fixed.
My best guess, without having the lock in hand, is that the frizzen is too soft. If you want to try rehardening it yourself, have at it. But, from my experience I have found that only about one guy in ten is able properly harden one of these frizzens. Even my assemblers have trouble getting them right 100% of the time, obviously.
As always, if you get one of our locks that does not work properly, just send it back, and we will do everything we can to fix it.