Home built AR-15 = unreliable?

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That is a bit presumptuous. Unless I'm playing devil's advocate with a former employee *ducks*.

I wasn't being presumptuous at all. They even published the problem on their website, said they were addressing it, yet the problems persisted unabated. I was the unfortunate owner of 4 such rifles, manufactured over a span of 4 years. Why did I keep buying them? I wanted to believe I could get Colt quality at a Bushmaster price. I couldn't, you couldn't, no one can.

Product testing may be an initial slow down,

Product testing isn't just pre-production. The good companies have QI/QC programs that provide for the ongoing testing of their parts to ensure that manufacturing standards are being met. The "bad" companies don't. It doesn't cost them more money to solve problems when they find them, because, well, they don't care, and they don't solve the problems. Meanwhile, people keep buying them.
 
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