I've gotten two Knockouts from Amazon, they were all fine. One of them rattled, the one I use currently (the other was a gift). I've said it before, but I haven't had an instance when I bought new stock from Amazon and actually gotten a used piece. Of course, I'd sooner buy from Dave, and any ZT I care to buy I certainly do, but he doesn't stock everything and I won't ask him to do my non-knife holiday shopping for me either. Well, at least not until I've been over to his place for dinner. /creepy
All that said, I've also often heard people say their screws came stripped, but not once have I ever actually run into a Kershaw with stripped screws. I've owned about...56 at last count, and if you have the right tools then one would find that the screws are often just fine. A more likely issue is that they strip out when you don't use the right bit, and considering you say your T6 is too small and your T7 is too big, you likely have the incorrect (and possibly poor quality) tools. The screw sizes vary. Most Kershaws indeed have the T6 clip/body screws and T8 pivot screw, but my orange Skyline takes a T10. So the the body screws on my 0550. It's just how it goes sometimes, and I never blame poor tools on the screws.
Just request a replacement, they'll send one out without needed the return right away. Then get some proper tools and a bit of grease. The rattle doesn't even imply that the grease is dried out.
The Knockout hasn't been in production long enough for the grease on the very first one to actually have dried out. Perhaps they didn't put enough in there to fully encase the torsion bar.
Calm down, return the knife, and try again. You didn't "get f***ed".
