OK, well sorry to hear of all these problems. I don't really know what I can say (hands thrown in air), I thought this was going to work out well. I replaced both side badges, and yes they were tight to fit, I did enlarge the holes and they pulled up to what I thought was acceptable. I guess I should have made it more obvious that the badges I received did not fit perfectly straight from the box.
As far as his business attitude, well I must say I do not know the owner of this business personally, but I am suprised at the reply he has made to your email, I thought he may try to explain the process and what might have caused the problems with reproducing badges, not brush you aside and probably alot of other customers from this website at the same time.
I can also let you know that I won't be involed in trying to help replicate any other part after this disasterous attempt.
I have attached a couple of pic's of my bike and if you look closely you can see I have enlarged the holes to make them fit. But please my bike is certainly not perfect and I can live with the imperfections.
Thanks Mick