The worst casts I got were the engine blocks on my Hyperions. Mutilated with horrible excess that robbed me of a lot of detail, I considered sending them into mongoose for replacements but the rest of the boxset was fine. The Nova was perfect, the Omegas needed a few snips here and there but overall to complain about two or three models seemed unnecessary so decided not to. The second worse I have seen were the wing slits on some Dilgar Targrath's and the verticle wing slot for a pair Vorchans. One had such a thick filling that I had to saw it out.
A fellow player has had to put alot more man hours into his Tinashi's and believe he had to replace a couple due to gaping mould holes. What added insult to Injury was the fact he got three wings of Frazi's rather than Raziks with his Centauri boxset.
I would not mind if the boxsets cost £10-£15 but the fact most sell for £50 its a bit of a jyp to have to repair models which should, in essence, be high quality to begin with. Further the fact that its become a case of 'Hit and Miss' regarding purchases means that I'm often put-off from buying, especially because I do alot of shopping online, its a good thing I came to these boards otherwise a Drakh Boxset with missing Mothership would have been purchased for a very disappointing B-Day present.
On the other hand some models are lovely. I recived a box of Chronos, a Dargan and EA Re-enforcements Boxset and all were perfect. The Dargan looked like it had just been cast (twas all shiny) and my faith at least took a step towards being restored. My Narn was largely intact though the G'Quans were fiddly.
*Edit*
Gah...Stands, I knew I forgot to add something.
Again Vorchans and Hyperions are my problem here. I don't own a drill (though that small present under the tree looks interesting enough) so i'm left with alot of stands and wonky, unuseable models. One thing i'd like to push for too...make sure models are weighted better. Trying to get a T'Loth to stand up before i put a stabiliser on it was so frustrating....
*End Edit*