I have had this problem on several of my flintlocks. At first I tried to prussian blue around the pan and attempted to file down the high spots, I only made things worse.
I had Mark Elliot relocate one frizzen screw hole for me for a better fit, he did a great job.
I watched a youtube video of a guy tuning the pan fit on a frizzen, he use marking dye and filed the frizzen high spots and not the pan. I gave this a try and found I much more precise than trying to level a beat up pan. I thought the frizzen would be too hard to file but it wasn't, the hardness makes you go slowly.
I had Mark Elliot relocate one frizzen screw hole for me for a better fit, he did a great job.
I watched a youtube video of a guy tuning the pan fit on a frizzen, he use marking dye and filed the frizzen high spots and not the pan. I gave this a try and found I much more precise than trying to level a beat up pan. I thought the frizzen would be too hard to file but it wasn't, the hardness makes you go slowly.