That is even more expansion/contraction than I would have expected and I'm sure all of what you say is completely accurate, Craig, but the main reason for the fitting issue is that I had version 1 racks and then he changed the design of the shelves when he created a version 2 rack. When he originally replaced the shelves but not the posts, he told me that the v.2 shelves were slightly larger but thought they would work with the v.1 posts. The new shelves then sat in my house in essentially the same room as the racks for 5 months ( ) so I would think that humidity issues should have equalized by then. Who knows, but I think the v.2 units have different enough tolerances that it really doesn't work to mix and match with the old version.
He is picking up all the pieces tomorrow and returning assembled racks early next week. Pretty damn good service, especially with the New Year's holiday in the middle.