I'm Still trying to figure out why the saw's failure would be any fault of yours Brett.
It ran after you ported it for a year of commercial work. Wouldn't most issues secondary to an improper port job evidence themselves immediately?
How long does a stock 661 usually last your customer?
I'd like to know the answer about how long a porter is "on the hook" for repairs once a running saw leaves his shop. Is it 6 months, a year, forever?
Sounds like your customer is reasonable and was able to be more productive with your saw than a stock one. Even if he paid the cost of a new saw for the port job, if it made him more productive, it was likely still worth it.
I can't wait to hear what you find wrong with the saw. I'm betting the failure had nothing to directly do with your port job.