Bolt catch problem resolved!
I am going to call it worst case tolerance stack up. All it took was filing 0.006" off the right place on the bolt catch. I continued to think about @Craig6 saying
What was holding it back was the bottom “lock button” was bottoming out against the lower reciever. So either the pivot hole was drilled slightly off, the receiver was milled slightly off, or something else, but I am glad this is over 
Don’t know if 6 thousands was exact right amount to remove, but it worked.
