hoo boy, it's snowing and i've got kayak fever, just trying to say that the problem is solvable. the characterization of "poor quality" doesn't help Will, I can't tell from wills post how much "slightly different" is. 1/32"?,1/8"?

In my experience when problem solving descends to name calling then problem solving stops.

So not sure what kind of response you're expecting on the bike analogy. Motobecanes had interesting quality control. Still had to put air in the tire. I think lifes generally a miracle let alone be able to talk to pure strangers over this board or be able to make an epoxy/glass reinforced wood boat. Any fog out in the valley?