I hope the "term" freak out didnt come off as a negative thing. Honestly I would be. Thats why I put the smiley face on it. I hate to hear things like this happening especially to a new owner of a product, especially such a product like the Provari because it is so highly prized. I dont have a Provari nor am I really into them, but I know they are a good product.
But I do know enough to say that if there is something down there on the battery contact blocking the power from Battery to the connection of the carto/atty etc. You are not going to get either power to fire it or its going to be intermittent. It sounds like a definate and valid concern. I would think that the makers and vendors of the Provari hear your problem that there is no way they can say you might be wrong, and any way with their reputation and large sales they would not want anyone with negative feelings on their product.
And Im with you, I would not scrape or put anything down there, you dont want any reason for them to say you messed with it and cancel the warranty. I really feel for you, you have no idea how many times this kinda situation happens to be. Seems that if there is a one in a billion flawed item out there I end up with it.
And another thing, vent all you want, it really helps, and venting here is the best place to do it. We are here to help you. And if it seems everyone is sort of repeating themselves with all the "try this" or "maybe its this" is because we all have been there and done that. Plus with a Provari its probably unheard of that there could be a defect. I does happen, Ive seen other thread with those rare problematic Provaris.
Vent, vent vent vent. etc.