LampShadeActual I know what you are saying, and the possibility of these types of issues would dissuade me heavily from dropping money on such an expensive pistol, but manufacturing is manufacturing...EVERY manufacturer, every gun company (including HK, Glock, and in this case, Beretta) can, has, and at some point, will again, let out a bad gun. We all wish it never happens, the manufacturers even wish it never happens, but it does. It hurts a lot less when it is a cheap $350 or so gun, than when it is a $1000 or so gun that is faulty out of the box from the factory, but it can and does happen no matter how much the gun costs.
I don't know obviously the particular story or scenario behind the mess of a gun that the OP received initially, and of course it is hard for us sitting here reading this thread to believe a gun like that could get out the door without being noticed....but, activity inside metal machining shops/manufacturing facilities when things are balls-to-the-wall to meet takt times can be absolutely crazy. I'm not saying it's ok that a bad gun got out, it is not, but despite Beretta's (as well as every other manufacturer's efforts) it is going to happen from time to time. The best a company can do is try to look at their processes, the frequencies of their gaging checks, etc. to minimize returns/warranty issues, and make things right for the customer if his purchase was bad from the factory., the way that Beretta did here.