Did you use light piano wire? I don't remember the gage/number/size or whatever, but I have more if it than I will ever have use for. I can send you some for nothin'. The thing is, if it's too light, it won't function at all. I'd say you should be able to get it down to 3.5. Another option I've done a few times is taper the sides of the sear so there is less sear engaging the trigger. Maybe take it down about 10% on either side. That way you still have enough spring tension to hold everything in place, but less surface area for the sear engagement. A bit unorthodox, I know, but it's worked alright for me on a few.
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