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are they really that bad?
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Replace the FCG with factory Colt parts. If you have KNS pins, rip that worthless shit out of there.
This +1 except for KNS pins being POS. Just remove them and replace with regular pins and NIB FCG (including sear) while diagnosing the issue.
are they really that bad?
I believe the bad reputation was with original gen 1 "dogbone" variant of the KNS anti-rotation pins which had a hammer pin which was hollow and which attached to the trigger pin via threaded screws. On the Gen 1 setup the hammer pin also had oil holes which were problematic. Specifically the hollow hammer pin would break where the oil holes were located, especially if used on 9MM.
The current "2nd" generation (and by current have been around for probably close to 10 years) the hammer pin is solid with no oil holes and has "tabs" on the side so there is no screws tapped into it. I am still not sure why they put the anti-walk detent in the center of the hammer pin since that is almost invariably where hammer pins break and the anti-walk detent is pointless on a KNS anti-rotation pin since they cant walk. Why put a detent weak spot on the pin if it doesn't buy you anything is beyond me. However, the solid KNS hammer pin is technically no weaker than a factory stainless pin but could be stronger if the spring detent in the middle was removed since its not needed.
The trigger pin on the Gen2 is still is hollow, has the oil holes and the "legs" are held on via screws to the trigger pin. I have never heard of a KNS trigger pin breaking and if it did it would be immediately obvious to the shooter as the trigger would wobble even with the legs still attached.
I have had a set of the second generation KNS pins with the solid hammer pin on a RR for probably 7 years or more and have never had any issues.
Only hammer pins I have ever broken were on a 9MM setup using standard (non-stainless) pins. Upgraded to OEM Colt Stainless pins on my 9MM rig and have never broken them over many years of shooting.