Hey guys picked up my first AK. It's a Century AK63DS, the stamped version of the milled 63D. A problem I'm having with it is the over travel on the safety going way past the fire position when sweeping from safe to fire. The safety lever is not loose or overly tight, feels just right to me. I'm not he-man slamming it to fire but I am applying some positive force to get it moving.

The small detent in the lever and receiver is there and catches but easily overcome. I did notice that the lever also has a flared half circle stop notch to mate up with the stop notch coming from the trigger guard. It's not aligned though and barely catching.  Is there a recommended fix for this or should I try another safety lever?

I was thinking of remove the lever and hitting the flared area with a punch so it has more area to catch.

...or bend that little tab out just a hair.

You could enlarge the notch, but you should definitely bend the lever inwards to give it more tension, it shouldn't go past the safety overtravel stop, the notches are meant to be easily selected.

I just noticed on my lever I do not have that small oval cutout as seen in OP's pic but mine stops solid when it hits the overtravel tab

Just take the top cover off, rotate the selector lever up above the receiver and slightly bend the lever inwards. Keep doing this a little at a time until you are satisfied with the tightness of it.