drjdog,
Before you sell your gun, how about this: keep calling USFA till you get the receptionist. When you talk to her, insist on talking to the smith who worked on your gun (or any other smith) because Gary's been too busy to call or email you back. Then, if you succeed in getting him on the line, offer to email pics showing the problems with fit, screws, etc. Gary is a middleman. He has to talk to the smith, then relay info to you. If you can skip the middle and go to the source, I really think you'll get a solution to the problem.
The reason I suggest that is b/c I had a pretty good feeling about my conversation with the smith. Most other companies would have just shipped the guns back to me saying "headspace is within factory tolerances using WW brass." Instead, the smith spent 2 days trying out different fixes, tracking down a black powder expert, and finally, calling me to discuss the problem. And when he called he didn't just tell me "tough luck, I'm sending them back." He said he'd keep trying to find a solution. The call did a lot to restore my faith in USFA. (I have been blown off before by other firearms companies, so I value the experience I'm having with USFA. I'm still pissed about how long this is taking, but that's life, I'll get over it.)
Keep us posted.
JD