When the slide is fully forward, it fires just find.
When it is rearwards just that hair, the disconnector is pushed low enough that it starts to engage the sear, but when the sear swings far enough it slips off the bottom. Thus, the hammer falls but the sear starts to reset and it ends up in half cock.
You are correct, except it fires to half cock when the slide is back a tad. That is not normal. I will add checking the upper lug engagement again to my list. At one point I had all these numbers written down, but in a recent move I haven't been able to locate everything yet.
I beleive I may have a headspace issue, based on the measurements of my chamber that I took. Since I can hand cycle the gun all day and not recreate the half-cock firing problem (that is, it only happens with real ammo present), I think that may be what is causing the issue. A longer round goes in, it bumps the slide back that hair, and I get a fire to half cock....
So I need to find or replace my go-gauge and see if that is a problem or not. If it is, I fix it and see if the problem re-occurs. If it doesn't grand. If it does, then..well that is why I'm still looking for things to double (triple, quadruple, pentuple) check.
-Brian