I have bent a coupla of hammers with fairly good results. I have not stretched one, but there are other fixes for the clearance issue.
Decide how much and which way the hammer needs to bend, clamp the hammer in a vise, heat the the bottom of the neck, with top jaw and screw in place, to prevent distortion of the screw hole, and bend with a wrench.
Hammers are soft steel and do not require heat treating.
Check to insure that the flint points to the center of the pan, then deal with the flint/frizzen clearance.
Some guns require a short flint, but the issue of clearance between flint and frizzen at half cock can be remedied if there is clearance between the flint and the pan when the hammer is fully depressed.
unfortunately, it is sometimes not feasable, time and equipment wise, to try to compensate for lack of clearance between the pan and flint. So's we sometimes just gotta buy short flints from track of the wolf, or reduce the length of those flints we have.
IF the flint does not bash into the pan when the hammer is fully depressed, you can make a new sear with a slightly longer nose. A longer nose will cause the hammer to rotate farther back, giving more clearance between the flint and frizzen, at half cock.
IF you have a welder, the step on the back of the hammer can be welded and refiled so that the hammer makes contact with the top of the lockplate
with the hammer at a higher angle, providing that clearance between the flint and the pan.
Lock parts are cast steel, so that is an issue when building up lock parts.
The nose of the sear can be ground down a bit, and new steel brazed on to form a longer nose. Brazing will hold up well in this application. Welding the nose will distort the front part of the sear, often including the pivot hole, so brazing would be the way to go in building up the sear nose.
I think Thunder Ridge Muzzleloading sells parts for Petersoli locks. Track of the Wolf carries parts that can be made to work, as does Dixie Gun Works.
IMHO, I would try Thunder Ridge to see if they have the necessary parts. Be aware that new Petersoli parts may or may not fit correctly.
The good thing about Track of the Wolf's catalog is that their photos of parts are full size, so you can match a new cock or sear to yours.
All of those companies have web pages and should come up with a simple search.
You will probably have to drill and file the square mounting hole and top jaw screw hole in a blank hammer, or drill a pivot hole on a new sear, but it might be easier to go that way, as opposed to making new parts, or heavily modifying the old ones. IMHO, bending the hammer is a minor modification.
IF you do find a new sear blank that will work, it will need to be heat treated, but that is easily done.
Track may, or may not, have a finished sear with a nose slightly longer than the one on your lock.
IMHO, making a new sear is not difficult. The only tools required are a hack saw, file, and a drill. A drill press would be nice, but not absolutely necessary.
These old guns can be pure joy to shoot and mess with. They can also be pure hell when you get a bad lock.
Bad locks CAN be made to perform as well as high quality locks, but IMHO, the time and effort is often not worth the aggravation.
J.D.