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You are wrong on the NICS issue.
If it's for the purposes of repair then a 4473 is not required. See
ATF's FFL Quick Reference Guide, Page 13 and 14. Look at the sample bound book, specifically entries 5 and 10. Customer brings in a broken Remington 870, FFL sends it out to another FFL for purposes of repair and it comes back from the gunsmithing FFL. Dealer logs it back in from the gunsmithing FFL and then it goes right back to the customer (no 4473 required).
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You should let your customer just send it back. He is legally allowed to ship it back for repair and they can ship it directly back to him. Not usps, but still....
You do realize if you do ship it for him you have to log it in, back out to oem, in when it returns and then 4473 it back to him? What if he has a nics problem? How will you make $ doing this even if all goes well? What happens if it gets lost in transit? If you want to do it as customer service I guess... still id just tell him to ship it back himself so the transfers dont take place. Too much risk....
You are wrong on the NICS issue.
If it's for the purposes of repair then a 4473 is not required. See
ATF's FFL Quick Reference Guide, Page 13 and 14. Look at the sample bound book, specifically entries 5 and 10. Customer brings in a broken Remington 870, FFL sends it out to another FFL for purposes of repair and it comes back from the gunsmithing FFL. Dealer logs it back in from the gunsmithing FFL and then it goes right back to the customer (no 4473 required).
I didn't catch the second transfer when I looked at the example yesterday.
So here's what I take from it all.
I get it from individual and list as acquisition, then send to Taurus and list as disposition.
Then when it comes back, it comes back in as acquisition from Taurus and disposition back out to individual. No 4473 needed.
Now my next question, do you notate in your book that it's a repair as a reminder so on the next inspection it doesn't appear that it's a regular transfer and don't have a 4473, or maybe have them fill a 4473 and don't worry about background check and notate on 4473 in the additional comment section it was a warranty return.