Yikes. I understand that there are many potentially-valid reasons not to work on a gun--but for a business to come across as in-your-face belligerent is not a way to win customers. I wish the original poster the best of luck--I've been there too. As for Mr. Searcy, I hope his health is better and that he considers moderating his tone--people are fair and will give you a second chance if you don't come across as a bully.
BTW, JJ at Champlin's would have been my recommendation too--I have had work done by him in the past on a C&H double and there's nobody better in the USA IMHO.
Just my opinion here based on what I've heard on the gun 2nd hand. I believe Mr. Searcy tried to deal with the deformation of brass by assuming there was something wrong with the chamber. (he was probably right) It sounds like he chose to file/mill the breech face of the barrels so he could chamber-ream the chambers once more in hopes of cleaning up whatever was causing the brass to be ruined. (I believe he shortened the barrels from the breach) If that is true, it sounds like Mr. Searcy didn't consider the dozen things that happen when you try such an unusual repair. 1.) Forend hook/loop match up to forend changes. 2.) Ejector timing is now off. 3.) Cocking/Ejector dogs are now too long. 4.) Top lever doesn't bite the 1st or second bite at same engagement point anymore. 5.) Ejector spur is now thinner from the machining. 6.) Regulation changes because harmonics are different with all the slop introduced until points 1-5 are re-addressed. 7.) The length of ejector spur travel must be increased proportional to the amount of breach face removed.
I'm confident that Mr. Searcy didn't address any of these issues IF that is indeed what he has done for a repair. I can see before-and-after photos of the gun and the top lever doesn't bite correctly. (His alleged repair approach would do that) I can see that the top lever screw (a pitched screw) looks horrible and is out of time due to the geometry changes of lock up. (His alleged repair approach would do that too) A new, expensive screw would have been required. All the screws are out of time in the after-searcy repair pictures. (His alleged repair approach would do that too) Did he over/under torque them? Not give a crap and mix them up? Did he have to dress down the underbite after shortening the barrels, thus the screws don't time? Dunno. Clearly not the way the gun was in the "before" photos on this site.
What should have happened is the gun should have received new barrels by Mr. Searcy if the gun was made with defective chambers, that's a latent maker defect, not a wear or abuse based defect. The work allegedly done created a domino effect of many, many additional problems as a result of what I'm told (and I genuinely believe) was done by Mr. Searcy as he attempted a repair other than doing it the right way. Sadly, because its a 500/416 and the barrels are thin, there was no option to change the chamber and re-rifle to say .450-400, .470, or .500 as would have been possible with other cartridges...cruel twist of fate. So knowing you can't reuse the barrels, a set-back the barrels approach appears to have been chosen by Searcy which is honestly, a desperation play, not something a maker ought to do.
If it were me and I wanted to maximize my profit and I were Mr. Searcy, I would have taken the gun back, replaced it with another gun of used condition, and called it a day. I would have then reused the action with new barrels for a future customer order. I think the original defect, plus Matt's experience trying to get it fixed, plus Mr. Searcy effectively causing tortious interference on Matt's sale by saying he would never warranty or repair this gun for anyone (killing the value, harming Matt's sale), all are really unfortunate things that don't speak well for Mr. Searcy.
Matt just wants to recover some of his money. Would someone that has time and patience to rebuild this rifle in light of what needs doing, please buy it from him for a fair price?