hello froghunter -
i would call the factory and make them really aware of your return. my experience is that they have always been quick to turn around warrantee repairs.
i've had 2 handi's fail from fatigue. the first was an SB2 frame that has a bunch of barrels. the firing broke after approximately mixed 2,000 rounds. it broke while shooting the 410 barrel. the factory repaired it for free.
the second was a 357 mag handi that had a similar failure at about 2,500 very mild cast bullet semiwadcutter rounds, the spring for the firing pin failed and "No Body" or "I Didn't Do It" closed the receiver with the firing pin sticking out. the pin bent then broke when the shell casing hit it. but once again it was a free repair. this gun is the visitors plicking gun at the camp that gets a lot of use and was less than a year old when. it was fixed in june or 2005 and has had another 15 pound box of star 148 grain wadcutter hand loads pumped through it since with no failures.
all guns break, some after 500 rounds some after 50,000 rounds. springs, firing pins, trigger sets, barrel selectors, etc. break not every day, not a big deal at all. if you really depend on your handi, for trap league or for lunch, i would simply get a backup and leave it in the closet for that day when that little pin or spring breaks again. (excuse #1,962 to get another handi !)
hope this helps !
sg