There are 3 things I'd like to mention, one of which was touched on by someone else, that everyone should consider.
* Cooling is very important to keep components safe, but it is also a huge selling point. If manufacturers thought they could sell a few million more cards by slapping a 25 inch box fan on top of the card, they'd do it. So, it is plausible that Leadtek actually has more cooling than they really need.
* 2nd, manufacturers/distributors/retailers aren't stupid. They know the reality is that a percentage of the returns aren't legitimate. They also know that many people are scraping cash together for months to buy their upgrades, and accidentally damaging your equipment is more than just a little frustrating; bottom line, people will return the parts.
So, given this reality, the industry has this added cost built into the price, up front; it would be stupid not to. Like it or not, the cost is built in and always will be, so you may as well take advantage of it. Kind of like paying taxes for services that you'll never use.......until you do.
* 3rd (this was touched on a little), a company's return policy is designed for more than just handling defective products. It *is* a selling point. A company that will take any kind of return attracts a lot of customers, because they know they are safe no matter what. Many people are willing to spend more money on a product if the company has better return policy.
The bottom line: It's how the system works. You may not like it, but there it is. My opinion: Call them or email them anonymously and tell them the whole story, just to see what they say.
Either way, ship it back and tell 'em it's broke.........you already payed for it, you just didn't know it.
Btw, I used to work at Sears in the RMA dept. As you may know, Sears has long had a "Satisfaction Guaranteed" policy. If you gripe enough, you'll get what you want, even if they know it's pure BS. Yes, they lose some on customers that are pure sleezballs, but they attract a boat load of people that like the security the guarantee affords.