So the OP hates having to send back his knife for repair or replacement, because he is really busy and it is inconvenient to do so. I bet he has spent more time writing and reading this thread than it would have taken to box it up and drive over to the UPS/Post Office, so much for being too busy.
Ahhh but I have a solution, he should buy his knives only from brick and mortar stores he can visit in person. That way he can personally check fit and finish and other QC issues for himself, this should help minimize any "hurt feelings"
I have had two dealings with Spyderco customer service, one was over a Dodo that did not lock properly, phone rep said they had moved to using a stronger spring to fix the problem so I sent it in. The other was Endura that had developed blade play over a few years, this was one of the plastic clip models, and they sent me a replacement model with the now standard steel clip I was very happy with that exchange. Yeah it is kind of a pain to send knives back but
as long as their customer service takes good care of me, and it happens infrequently I am just fine with it.