Chuck,
This is too bad. Did the plater not know about fit when beginning the process? Sounds like they were not that experienced in these kinds of trim parts, and or just made some bad choices here.
It was some years ago now, but I used three different chrome platers for various parts of the car (all the trim was replated by two of the platers; the bumpers by a third) and we did not have any fit issues anywhere. I'd say your experience is the exception. Remember, the parts were chromed originally, so some thickness is being removed in prep. Typically you might get a thicker plating job than OEM, but there should be plenty of room (as measured in thousands of an inch!) for a "thicker coat".
Sounds like you got the problems solved by replacement but you should circle back with them (if you have not already) and let them know what happened. If you used a Dremel you compromised the chrome plate...compromised chrome is one reason for redoing it in the first place.
It was hard to see in the photo exactly what your issue was but I relied on your hands-on description.
