HUNTS, I would call em tomorrow and ask for Gordon, explain to him exactly what's happening and ask that it be fixed, also ask for them to pick up the cost of return shipping which you should have done the first time, they'll either offer to reimburse you or issue a call tag for UPS to pick it up. You should also include a detailed note to Jon the gunsmith so he knows exactly what the problem is. If they can't fix it with either a new barrel, ask for a refund, it's been done before. Just be nice when you talk to them, or you won't be happy with the results.
Tim