Carrie Anne, I am so sorry to hear this! Neither Barry nor I had any problems of this sort at all. As you know, I did have to send mine back to shorten the top tube, which was indeed annoying since I'd specified exactly how long to make it, but I guess they didn't believe that anyone of my height could possibly really want a 19" top tube! I did talk to a couple of different people at Bike Friday about that until they really "got it" about WSD, as well as wrote up my experience in a girlbike.com review. They did make it right and paid for shipping both ways without my even having to ask.
We didn't have any mechanical problems at all and have never had to call for service. I am not sure if they have hired some bad folks there or what since we got our bikes in 2004. They should definitely make everything right at their expense, but yes, it is a royal pain to have to pack them all back up and ship them back. So sorry.
As for going slower, ours were slower than our road bikes, but it was really an apples and oranges thing for us since they were also slightly heavier than our carbon roadies, and with wider tires, so we wouldn't have expected them to be quite as fast. We can still ride fast on them when they are stripped of racks, fenders, bags, etc, though. I rode mine once on a Tarwheels line and kept up in a fast B-paced paceline, so I am not sure why your husband's would be slower unless it is heavier than his current bike or if he has a more upright posture, increasing wind drag. I definitely did not buy my Crusoe for speed, though, but for comfort and touring. The "fast" Fridays are the Pocket Rocket Pro and Air Friday, which have skinnier rims and tires.
Keep us posted -- I am so sorry!
Emily
Emily
2011 Jamis Dakar XC "Toto" - Selle Italia Ldy Gel Flow
2007 Trek Pilot 5.0 WSD "Gloria" - Selle Italia Diva Gel Flow
2004 Bike Friday Petite Pocket Crusoe - Selle Italia Diva Gel Flow