Here are some photos of my rig. I was able to place a nickel in between my safty and the barrel and the safty never rubs the gun barrel. All my components fit snug and nothing is loose. I even looked at my paint job and I can say there are no bubbles in the paint and it doen not come off as I tried to scape the underside of the barrel with my thumbnail. You just got abad egg that's all and I don't blame you for sending it back considering what these go for. I would still send photos or an email to Knight and see if they can explain what happened. I checked my TK and it does have a plastic trigger guard but it is thick and stout and not cheap by any means asI have dropped this gun several times before without breaking it.

http://i126.photobucket.com/albums/p119/gotbuck1127/100_1828-rev.jpg

http://i126.photobucket.com/albums/p119/gotbuck1127/100_1827-rev.jpg

http://i126.photobucket.com/albums/p119/gotbuck1127/100_1829-rev.jpg

http://i126.photobucket.com/albums/p119/gotbuck1127/100_1830-rev.jpg

I also have Traditions guns and they are great as well. Let us know how your next gun shoots.