......YMMV, but my experience with Cosmic Ears has been a disaster.
Damn, sorry to hear that Starky.
LIke you I'm a Cosmic 'early adopter', also like you Phil deemed my impressions unworthy.
I too opted for the 'best guess' approach, rather than getting more impressions done ( mine were DIY and had definite flaws ).
Sadly for you our experiences from that point on were very different, as my HY3 came fairly promptly, fit reasonably well, and sounded great!
I've now had three pairs of CIEMS from Cosmic ( all from those 'faulty' impressions ), and although the fit was good on the first ones I've requested
tiny changes to the fit of each subsequent pair and the most recent pair fit superbly, which indicates to me that Phil has very fine control over the fit.
Please don't think that I'm posting this to be an apologist for poor customer service, I really hate being let down by people who have taken my hard earned cash too, and I have experience of that too( outside of this hobby thankfully ) .
However I have great faith in Phil and am sure that he busts a gut to provide the best results he can.
My advice here would be to stick with it and try contacting him again to attempt a fix.
I get the impression from all I've read here on Head-Fi that CIEM's can be a bit of a minefield regardless of the vendor.
I've had a very easy experience with all three of mine thanks to Phil ( barring my HY3's getting smashed by a dog, but Phil went out of his way to help me out despite the accident being no fault of his ) and I'm waiting for the HY5 to become available in a state of high excitement, which will be my fourth set of CIEM's! ( I only ever intended to get one, damn you Head-Fi )
I really hope that you end up as happy with your CIEM's as I am with mine ( sorry, that's not meant to sound as smug as it might come across ).
It sounds like your patience has been sorely tested, and although I wouldn't quite say that's 'par for the course' with CIEM's, I do think it's more common than with any other product 'field' within Head-Fi ( except maybe the wait for announced but as-yet-unavailable-DAP's! ) and you're not alone.
I do get the impression that Phil puts plenty of effort in to these sort of situations though, witness the lengths he went to with other contributors to this thread!
Good luck Starky, I hope the final result is worth it to you.