It's really shocking to hear about this. My Knight Bighorn has never been a problem, but these issues you're pointing out are making me nervous for the day that it does. It's a little nervewracking to know that if I need a new BP, I may not get the same size as I had before. The fact that they are so far off makes me wonder who the heck is manufacturing these things. Most of the local machine shops are dealing in fractions of thousandths, so how they can be off by as much as 4 thousandths on the "newer" design?
I'm REALLY sorry you're going through this Bob. Thank you very much for posting this though - I truly hope that Knight as a company sees this review and starts taking a second look at their QA.
Curtis