Just built a new lower (Spike's) with a RRA kit and RRA NM 2-stage trigger.  Also just read the thread over on the Build it Yourself section of the forum.

http://www.ar15.com/forums/topic.html?b=3&f=4&t=392901

Safety out, hammer falls.  Safety in on fire, no go.  In the thread, the person with the problem filed a bit off the flat of the safety to allow the tail of the trigger to rise high enough to allow the sear to release and the hammer to fall.

1.  Is a file the best way to take the metal off?
2.  File & test, file & test on the amount removed?
3.  Should the surface be dressed with a stone or is touchup with a fine file sufficient.

I know this isn't rocket science but...
Thanks for the help!

Bruce

Well, after looking at what to do I figured a $120 trigger unit with no implied warranty vs. a $15 safety.  After about 15 minutes with a file, the flat on the safety was down enough to allow safe and proper operation of the trigger group.  Then, the trigger group can be used in any lower, and all I lose is the safety.  With the grip backed off about a quarter inch, the detent drops and the spring is moved to the left a bit allowing the safety in and out quickly for fitting purposes.  How simple can it be.  The hardest thing was having the patience to not hurry the job.  I thought about waiting for a solution, then decided what the heck, it's the first build, I'll learn from it whatever I do.

Thanks for the input!Bruce