Dick had a few of the 275lb 57's with small cracks next to the side shelf that he was selling at a greatly reduced price. They still had a full warranty. They had the upsetting block too but at the price he was offering, who cares. I use the upsetting block on occasions but I have a large piece of steel I use more often.
You are very correct about the options, I use the thinner flat horn more often than you can imagine. All in all, it was an expensive purchase but if you are in business you'll repay the cost very quickly.