I've read enough of it... 100+ posts and counting (half by the OP)? on this "issue"? that alone tells me volumes about the nature of the person complaining about this issue; they won't let anything simply be. I see the same thing in forums about photography gear - people getting all myopic about the quality of the extreme corners of their lenses and so forth (i.e. pixel-peepers).
I've dealt with customers like this in my line of work (photography), and now simply avoid them if possible. If someone starts asking all this detailed information about my gear and workflow and so forth, I realize they'll never be satisfied with anything, and just walk. Sure, they're paying sometimes thousands of $ for the work I do, but I don't need those headaches. I have good friends who deal with the same kind of thing in general contracting work - nightmare customers who freak out if one bit of caulking is crooked, etc.
If this was really a bad problem, you'd be seeing volumes about it all over the web. If you truly had an oddball defective unit, you'd have gotten it replaced already, and moved on...