So is it still not completing the DA cycle or is it doing something different with the new triggerbar?
When it doesn't release in DA, does the hammer spring force the trigger forward to the resting position for DA? Does it drop to half cock? Does it revert to SA (does the hammer stay cocked)?
Did you touch the Disconnector at all during your polishing?
How much material did you remove when polishing? You must have been fairly agressive as it altered the timing. A little goes a long way in smithin, the surfaces don't need to be mirror.
Cheers,
Toby