"Why do the gaps matter... or don't they?"
Good question.
I don't know the answer to that for sure, but my best guess is how one perceives (real or imagined) the knife in question.
For example;
I don't know if there are gaps in the springs/liners of my Yellow CV Soddie, and I have used that knife for years, but I immediately noticed the gap in my 2009 Forum knife and almost threw up when I saw it.
Aside from price (which I really believe to be secondary in this example, even though there is obvious difference in price), one of those knives was supposed to be a special limited run made for real knife knuts like us. The other is a (relatively) cheap knife that I use when I don't want to damage a nicer knife.
Obviously the more something costs, the finer you might expect it to be, but if I buy a knife that will be special to me I scrutinize more, regardless of price.
I think of that as more of a "me" problem. It doesn't bother me really that the run of the mill knives from a manufacturer can be expected to be inconsistent, I just know not to buy sight unseen, if I am going to care.
What does bother me is when a company says something like:
"Hey, look at these reproductions of 100 year old knives blah blah blah, heritage. Blah blah blah limited run of xxx pieces. Blah blah blah honor the original."
Maybe we are waxing poetic and knives were crap 100 years ago? I don't know, but based on the above pitch I would expect a real fine knife with no obvious flaws to a discriminating eye.
On any knife marketed as being "special", obvious gaps are not a "me" problem IMNSHO, and are intolerable as far as I am concerned.