Not an unusual problem for the be Bersa 380. It has extremely tight tolerances in that are, and are seldom a problem big enough to have addressed by a gunsmith. Took me several sessions of watching a movie or some rare TV program to get mine broke in a few years back. Get a good Teflon Lube and continue to work the decocker putting a drop of lube on it ever 25 or so cycles of working it.
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I have no problem with the idea of carrying a BT with the hammer down on a live round and the safety off. The looong DA trigger pull is safe enough. No different from carrying a 38 S&W snubbie revolver … even in a pocket. However, when I get my new BT Plus, I will work that safety until it smooths out notably, and most likely carry it with the safety on. Personally I hate DA trigger pulls because I can't hit the broad side of a barn that way and will only use that whenever ABSOLUTELY necessary and at less than 3 yards …. otherwise it will be thumb-cock the hammer and go SA on the first shot. So, for me, it will most likely require two actions … disengage the safety and thumb-cock the hammer. 
Some folks apparently get pretty good with double action triggers. Some say pull straight through with steady pressure and others say pull to the point you know the trigger breaks and then become more delicate. If you need the pistol in a great hurry, your target will probably be pretty darn close and you will be pointing, not aiming. If not close, you will have time to thumb the hammer back. I bought a thunder a month or two ago and like everyone else I thought the decocker was horrendously hard to pivot. I pulled the mechanism (videos on youtube) and there were no burrs or grit so I cleaned and lubed it before reinstalling it. On the positive side, I feel this pistol is best carried with a round in the chamber then decocked and the safety moved back up to fire position. Pushing the decocker down accidentally with your thumb in a self defense situation would not be good with a thunder. A stiffer decocker lever makes that more difficult to do and it is really not necessary to decock one handed as that is done before holstering. When the pistol is decocked the hammer is not sitting on the firing pin as it would be when someone decocks with the trigger and thumb pressure on the hammer (not recommended). My HK USP has three positions, SAFE being up like a 1911, FIRE in the middle and DECOCK in the down position. On the HK the lever comes back up to FIRE automatically once you let go of it. If I were to accidentally push the lever down it would not affect anything as it is already carried in the decock position and is ready to fire in double action. I prefer that but then the Thunder does not cost what an HK does. Because of the way the Thunder safety works, I much prefer it be a bit stiff. After all you should only be using it once every time you put the pistol in its holster. I personally believe holsters should be molded to guarantee that the safety lever stays where you want it while holstered. On a 1911 I would want the holster to make it impossible for the safety to move down into FIRE position accidentally because of body motion throughout the day. On my HK I'd want it to hod the lever in SAFE of FIRE, depending if I wanted to carry cocked and locked or decocked with double action. On a Thunder I would want it to stop the lever from moving down into decock/safe position. Who wants to pull a pistol expecting a long DA trigger pull to find the lever shifted into SAFE and nothing happens when the trigger is pulled. That stiff lever is your friend as long as it functions.I have no problem with the idea of carrying a BT with the hammer down on a live round and the safety off. The looong DA trigger pull is safe enough. No different from carrying a 38 S&W snubbie revolver … even in a pocket. However, when I get my new BT Plus, I will work that safety until it smooths out notably, and most likely carry it with the safety on. Personally I hate DA trigger pulls because I can't hit the broad side of a barn that way and will only use that whenever ABSOLUTELY necessary and at less than 3 yards …. otherwise it will be thumb-cock the hammer and go SA on the first shot. So, for me, it will most likely require two actions … disengage the safety and thumb-cock the hammer.
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