I consider myself lucky that the service department from festool Netherlands has things better under control than their UK counterparts. I have send in a few items under the 3 year warranty program (my ts55, my ebq1010, the heavy duty ripfence of my CS70 and recently my kapex), in my case the problems were all minor, but I send them in because they were still in waranty; the festool dealers in Holland have special systainers, which are used to send the tools to the service department, so the original ones are never damaged. (they won't send them in, nor the attachments for the tool that aren't needed for the repair, you keep them). Festool charges the dealers for the transportation cost, but it's not much, and only 1 of my 3 dealers charged them through to me. (I think it was 4 ? to send my kapex back, they packed it in a very big box, filled with protection material; a year earlier I heard they charged my other dealer 16.50 to send the little router back, but that dealer ate the cost as service)
I think it takes some serious throwing around to break edges of systainers, and it won't do the tool inside any good either.
Did the festool rep that aranged you the new drill earlier give you his business card? It might be a good idea to contact him again (or better yet, have your dealer do it); since that rep knows of your previous experience.
I just read the after-sales service section of the festool.co.uk site, if you (or your dealer) still know the repair number, you can fill out a
customer feedback form
As for other people not having that drill, I spoke to a guy on the bus one of my dealers arranged to a building fair, and he bought a few for him and his crew at the time of the introduction, and didn't mention anything bad about them. I guess not to many of the European and Australian forummembers have one, and the American people that DO have them can't talk about it yet because it isn't released there yet. (I know Eli has one, and I doubt he would keep it quiet if his had similar problems)
I hope it will turn out well for you in the end, you had more than your share of problems with it already.