Didn't think I would post back in here since I went all a big ragey a while back (yes, it was indeed a bad day!)
Anyway, sent my One back to HTC for "repair" due to the gap problem. I thought I could live with it, but it bugged the hell out of me! Had a nice chap call me, an Escalation Manager saying that due to the time it's taken (6 days), would I mind a new HTC One, in Silver, unbranded. Said they would contact Orange to sort serial numbers etc. on my behalf. To be fair, my Orange one was unbranded too, but you never know when they will start brading them (probs when stock is plenty)
Annoyingly, that was on a Thursday, so it went out Friday and because couriers (most) don't do weekends, didn't arrive till monday. It's perfect!
Even came back with some .bak file on the internal storage (need to look into that), test pictures they had taken to ensure cam was working (will post later) and newer software! (I have two One's). The software isn't the "new" OTA update, but slightly newer than the other One I have. Not noticed any difference.
Now, I understand that this could well be a re-furb unit, but it honestly is perfect! No gaps, no overhangs, no dings, scratches, marks or anything. I honestly do think it's a new one.
Also, don't know if it's this software versioin, but NFC doesn't have a status/notfication icon in the status bar anymore (YAY!), cause that annoyed me somewhat! No difference in camera performance.
What IS annoying though, is that this unbranded handset wasn't first to get the new software update. To be fair, my Orange handset hasn't either, but ya know?