I tend to be partial to my older version. I'll second (or third, or whatever) the notion that the blade be kept just shy of 3", simply because if it's clearly even 1/16" short of 3, there's no room to be hassled. My friends laugh when I explain to them about Protech making switchblades that are 1 15/16" long to fit into California guidelines... but they fit, and they sell. So keeping the delica (or returning it) to just shy of 3" is probably a good idea.
I hadn't paid much attention to the fact that the newer models have a thinner cross section of FRN around the pivot, since I haven't really bothered to replace mine yet, but if folks are having issues with the thinner cross section, I'd recommend making it thicker. Mine has survived far more than it was intended to (including being thrown into trees, etc) with the thicker cross section. It was from circa 1992, I think, if you've gone through so many variations. It was an engraved run of 500 for Chesapeake Knife&Tool if that helps place it. But thicker is usually stronger, so if some folks have issues with the strength of FRN, a little more around the edges can't hurt.
Dunno... it's hard to really improve on the thing. I'd agree that affordability is a big part of this knife, so going too exotic with materials on a regular production run that wasn't a numbered piece like the CF delica would really hurt it as a model. But I can't see how a downgraded model would hurt, since the serrations just never quit. On top of that, a model in Aus-6 or 440A might even be affordable enough to make and sell that you could edge back into places like REI, and (without knowing anything about big chain markets) maybe even Wal-Mart? I'm not sure if that'd help or hinder Spyderco's reputation, but hey, wally world's a big market. And who knows... get someone hooked when they're still on a budget, and they'll likely look your way again when they can afford something more. I hate to point out how narrow minded some folks can get on some things, but for a lot of people, brand recognition carries a lot of weight... even if the brand isn't exactly holding up their standards. Witness the Frantic Ford/Chevy/Dodge rivalry, especially in the south, and you'll see what I mean. So weaning folks onto a spyderco diet in places like Wal-mart might help. Why the hell people still carry Gerbers I'll never know, mine never held and edge worth a damn, but Walmart carries plenty of those...
Beefing up the nylon around the pivot, and a shorter blade would make for a stronger, still affordable knife that fits comfortably within any 3" legal guidelines, and would still work just as hard as it always has. (IMHO)
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