Ok, so here is the update. I ran degreaser through the channel and applied a think coat of Aluma-Hyde. After it had cured for half an hour, I tested the fit of the bolt catch to the channel and it was tight again. Just the thin coating had messed it back up. I ran degreaser back through the channel and used a shop towel to clean out as much of the aluma-hyde as possible. I then very lightly covered the silver areas with a Birchwood-Casey Super Black marker. I waited about half an hour for it to dry and then coated the channel and the bolt catch with gun oil and reassembled. It moves very smoothly now. I once again borrowed the upper from my other AR and tested to see if the bolt would lock back. I cannot make it fail. Unless I run into issues when firing it, I am calling it fixed.
Yes, I realize that you always grind the cheap part. However, in this case the lower was rough and the bolt catch was smooth so I thought what I did was best in this case. I won't be able to test fire for a while. All the gun money has been spent and I have my wife's b-day coming up so it will be a month or two before I have the money for the Geissele trigger I want for it. Once it is installed, I'll test again. However, I don't foresee any issues.
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"We must all hang together, or assuredly we shall all hang separately." - Benjamin Franklin
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