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I'm replying here since the thread you linked to is five pages of what other revolver to buy.
My question is what exactly did Rossi tell you about your revolver, other than they wouldn't return it? Did it fail a drop test? Are they destroying it? Did they mail you an explanation? I'd be interested to know. I've heard recently of a few that were sent in, tested, cleaned, and returned. I'm wondering what made yours different.
The fellow who called did not give much in the ways of details and his manner of speaking was hard to follow. He was clearly reading from a scripted message. Basically, they said it was found to have the defect, which from what I read is that it fails drop test. He didn't say if they'd destroy it or not, but presumably they will. I did not receive any e-mail from them, though I did receive several form letters via post leading up to receiving the return sticker. They requested that I send the receiving FFL to a specific email address and to cite the work order number, which I did, but I did not receive any response to that. I asked them if they had a better option than the Taurus 605 because it is a very different revolver than the one I sent in and I was told unequivocally "no". Presumably, there will be some paperwork with the replacement and, if so, I'll post those details then. Hope that helps.