The barrel?  Or the slide?  Or the frame?

If I've found it, I don't know what I am seeing.

The lump on the second lug.

Okay.  How do I remove it?  Fine file?

The frame has poor machining on mine as well.  Lots of tool marks.

The wear on the slide lugs seems a bit odd to me for a gun that was recently refinished. My witness was cerakoted about 1k rounds ago and it has very little wear.  But each gun is different. 

Mine was cerakoted as well.  The barrel... Since fitting has had about 150 rounds through it - not the 300 I had previously guessed.  So that wear is all new, and in a very short time.  I wonder if the slide metal is soft... 

I am thinking that at the least I need to step up to an 18.5 recoil spring.  Not for recoil, but to slow down the unlock time.  As I had one on hand, that was an easy fix.  I also filed - very carefully - the small hump on the barrel lugs. (there was an even smaller one on the front lug)  I cleaned up the inside of the slide with a small, flat piece of metal - just cleaned up the pushed metal on the surface.

I will see if I get improved results later.

I did file it down, but was unable to shoot it this afternoon, to guage the results.

My question: Why did that occur in the first place?  Because filing it down is one thing...  Correcting the cause would be better.

No pictures right now, but I figured I should report: After cleaning up the barrel and slide lugs and installing an 18.5# recoil spring, the group is down to about 8" high.  Still more than I would like. 3-4" would be ideal.  I would guess that most of that drop came from the heavier recoil spring.

Recoil itself is still heavy and sharp, though slightly reduced. (18.5 spring)  Right after shooting the BHP, I shot my .45 1911...  If I am honest, they were about the same.  Slight edge to the .45, but that should be expected - it is a .45.  This is with heavier recoil springs in both guns.  The BHP is up to 18.5, and the 1911 is up to an 18.

After firing I disassemble it and inspected the lugs.  No further wear was noted.  Of course, it was only 24 rounds, but it is worth noting.

I have a 9mm 1911 as well, so I have some idea what a full-size all-steel 9mm should recoil like.  That 1911 is a pussycat.  The BHP is bordering on unpleasant.

Could you post some pics of your fired primers?

Tomorrow, yes.  I'll have to find one outside.

May I ask what you are thinking?

How does the firing pin stop look?   On some of the older guns I have seen them worn to the point that they do not provide enough resistance to help keep the gun locked until the pressure drops.  I've even seen a couple that were cracked and/or chipped.   If that is the culprit causing your gun to unlock too soon it is an easy fix. 

How does the firing pin stop look?   On some of the older guns I have seen them worn to the point that they do not provide enough resistance to help keep the gun locked until the pressure drops.  I've even seen a couple that were cracked and/or chipped.   If that is the culprit causing your gun to unlock too soon it is an easy fix. 

In my 10mm 1911's I run flat bottom stops for this specific reason.  If the firing pin stop is damaged I would suggest replacing it.  They are pretty cheap.  I haven't look for a flat bottom stop for the hi power...And I don't know if one for a 1911 could be adapted with enough file work.

Other than the details you noted with the primers, how does the fired brass look?  Any bulging back by the case head or signs of impending separation?  With the gun in battery is there enough tension on the slide stop pin to prevent moving it? 

Question: How high did it shoot BEFORE Jesse put on the new sights?

 It
The sight question is hard to answer, because the barrel was replaced at the same time.  The answer is: no worse than any other 6o'clock hold. it was a few inches high, and I didn't like that.
Unfortunately, the original barrel was lost in transit, when being shipped back to my FFL.

This is called , a "clue".  It shot "a few inches high" with the old barrel. Now it shoots WTF high with a new barrel. Hmmm.  Kaso, did it recoil so hard with the old barrel?  If I were to bet, it would be you have a bad barrel, or a badly fit barrel. And the increased recoil, together with the burrs, and the POI high, makes me wonder (and I am no gunsmith) if there is a problem with the bore.

Out of curiosity, who made the new barrel?