Give us a break sometimes.

Oh, now come on... didn't you know that once you take a job on you're supposed to wave your magic wand over it and cure every problem that the project will ever have from now 'til Kingdom Come? How is that being unreasonable?

If you're unwilling to reassemble and take the future problems on (which is understandable) then you could always take pics of the problem areas and detail everything extensively writing, keeping a copy and giving a copy to the customer. Then, if he shows up here (or another board) to bad mouth you, you can post the pics and what you've found and keep your reputation in tact.

Sorry to say, but I've been in your situation. It's a no-win situation. Customer won't pay for or supply the necessary parts to get the project done and then spends months badmouthing you for his or her decision.

A former boss of mine said it best. "The customer is always right. Most of the time, they're just unreasonable."