I called Dougs and they said its possible the welding on the jig at the plant could of been off. Still they refused to take the headers back because obviously I ruined these.
I can't believe that Doug's wouldn't retrun the headers. Sure you dinged them to make them fit...BUT if they were made properly, you wouldn't have had to "ding" them in the first place. They should have returned these if they were not made properly. Either way, they are scrap. Just because you "dinged" them does not make it ok for them to run crap at their plant...
You should have asked Dougs if we have to go to their plant and show them how to make quality parts and get their process under control. I hate how companies push us around because we only are buying one part a piece. This would never fly if they tried to send a part like that directly to a Chrysler Assembly plant. Supplier Quality would have shoved them back down their throat and written a defective material ticket (DM) against them. Three DM's in one year, and they will not be given any future contracts...
They would have had to identify every part in that lot (batch) and quarantine it and send in certified "good" stock to replace it. If they could not get their "clean" stock to the assembly plant in time, and caused them to stop the whole vehicle assembly line, they were charged $10,000 per minute that the assembly line could not be run because of their stock problems. That was part of my job for 10 years, finding "out of spec parts" and then getting them fixed. Once I proved the parts were out of spec, I would get Supplier Quality involved and let them do their "thing".