MarkA,
No I did not drill the hammer. But I did think about it. I think the hammer could be made lighter for a faster lock time, which would be good but I don't think you should mess too much with the internal parts of the Handi. They are investment castings. As such they tend to have a very hard exterior and a somewhat softer interior. I wish someone made an aluminum hammer extension. All the contact points should just be polished, not ground on. The surface of these parts if you look at them thru about 10X magnification, appears to have minute surface pits. Polish them on 400, 600 and 1200 grit "wet or dry" paper laid on a glass or steel plate is about all I think you should do to them. Just remember they are castings, not machined pieces of solid steel. Polish the pin holes and pins, lube them with a graphite or moly lube, polish the contact points and you will be a happy camper. Today I took the trigger out of my handi and streached the trigger return spring about 1/4 inch and re installed it. It is a bit better now. Still crisp but just not quite so light. Probably about 2# now. I also picked up a small spring today at a hardware store, just got the smallest they had. It was a bit too large for the trigger return spring but I cut it in half and used it to put inside the spring that seats the latching lug thingie. Can't remember just what it is called. This is ala Fred, double springs on this thing, gives a positive lock up. To remove the trigger group, all you need to remove is the two lower pins. One large one at the back of the trigger and the small one at the front of the trigger gard. To get it back in with no problem, cock the hammer, that takes putting your finger into the bottom of the receiver and moving the latching lug forward so the hammer will cock. Hold or tie the hammer back and insert the trigger group, with the slave pin holding it together, into the bottom of the receiver and push the large pin home, pushing the slave pin out at the same time. It is really a pretty simple system once you see how it all works.