Hello Friends,
Damn Will, that hurts just hearing about it. What a bummer. Sounds like you went the distance to make it good. Talk about a hit to one's material and shop time budget. Kudos to you for pulling it off. Or, have we now heard the
real reason you sold your fancy power equipment...to finance materials to get out from under that boondoggle?!

Sounds like you had a rough go of it a time or two too Ed. Sorry to hear about that!
I'm at the student/hobbyist level, so I can only empathize with everyone's efforts grappling with questions like this. Never-the less, I have had to deal with it in other ways, such as as a jeweler years ago.
I read in another thread where it was said if you can't afford the materials and time to make whatever you're selling, then you need to modify your business operations, such as scaling back, so you can. This is one (of
many) reasons I got out of the custom goldsmithing biz. I never could manage it well enough to afford the insurance and/or all the precious materials or their replacements. Even if the customer gave me the money or materials, if something went wrong, I'd have to make good on it. You'd be surprised how many insanely obscure and invisible places a diamond can fly into to hide, for instance.
Of course, we worked orders a little different in that biz. It often took several sessions with a customer throughout the making of the piece. Original consultations involved sketches, then often wax models, just to make sure everyone was on the same page. Then there was often a fitting prior to setting stones and finishing the piece. Customer involvement was a pretty good assurance they'd stand behind completing the purchase.
The suggestions to involve the customer prior to commencing on the job (and probably throughout the process) seem like good ones!
To some extent it sounds to me, behind this
deposit question might be for some folks an even simpler question. Should I take custom orders or not? A sister question to this might be, or should I further develop my retail outlets? For me, At this stage of my life, I am just too damn ADD to be able to stand behind a seller's commitment appropriately and follow through to fulfill a customer's expectations (whether paying up front or not). So I would categorically not go back into any custom business right now. Shoot, I can't even get a KITH done!
It sure is a pleasure and a privilege reading through all your posts. Thanks for taking the time!
All the best, Phil