Mike,
The only qualification I can offer to you is my trade. I have experienced just about every sort of situation and condition you can imagine involving roller chains. It's part of my business, but I don't think we need to be qualifying ourselves. I only offer what I know, same as you have. It's easy to get flustered, understood.
I have customers who will have items I've provided them wear prematurely. This situation demands that I KNOW what the cause of failures are. When chains fail in industry, where many facets of production can be effected, the fingers start pointing early. Sometimes when folks think they have conducted spotless preventive maintenance yet something failed, you can be sure there was a reason other than normal operation to blame. Being an engineer you surely know Murphy's points of law. :)
There are a limited amount of factors that can cause premature wear in a roller chain. Just putting your horse up wet once can sure expedite some surface wear, especially riding again thinking you lubed it the night before. (shrug) If I claim to have done everything I thought I have done over the years, it'd be a lie. I've also heard a few folks talk about how when they first got their bike they adjusted the chain to the manual, yet they felt that was wrong since their chains and bearings were worn in no time. I contend that the maual will only state things the OEM knows for fact. I'm certain that these guys didn't do something right to experience what they claimed.
To close ones mind off to the possibilities of misteaks means....aaa......no more degrees to obtain! :cool: