Well after 3 trips back they should have just replaced the gun. I mean for crying out loud it's a cheap gun and hardly worth the shipping back and forth to Springfield MA 4 times.

My next step would be to field strip the gun, and place the frame in a vice. Then using a hacksaw, cut the frame into 2 pieces. Then get the prepaid shipping label off their web site and send the frame back in. Include a nice letter asking if they could please fix it.