I think it's pathetic, when a scratch on a new product is considered normal. In my opinion, the fact that Grados are built by hand is no excuse. Many other products are hand built, and I'm pretty sure that they wouldn't get passed the final quality control inspection. Rolls Royce comes to mind. Heck!, I don't even think that a Honda would clear final inspection with a scratch on it's body.
Long story short. About week after I bought my new GS1000 I noticed had a 1/2'' scratch on the back of the right earcup. My salseman contacted Grado's rep who brought two ''new'' pairs in, for me to chose from, and they turned out having worse defects than the pair that I had, so I ended up keeping mine.
Since my GS1000 in 2006, I have bought four new pairs of Grados, and to save myself some grief, I simply try to avoid looking at them with scutiny.
I guess that the complaints are probably to few and far between, but if everyone complained, Grado would probably be do the apropriate changes to save themselves the trouble of dealing with many angry cotumers.
And don't forget that if you decide to keep a pair of headphone that have one, or more defects, a future buyer may try to grind you about it, and want to give you less money because of it.