Thanks guys for all the reponses.
I sent D-Box an email last week asking them for instructions from the tech on how to repair the unit myself as well as seeing if I could elevate my situation to someone else there. That was last week Tuesday and I haven't heard back yet. I resent the email yesterday so hopefully I'll get a response.
I bought the system as a DEMO back in 2007 but if I'm not mistaken it was inspected by D-Box and given another year warranty. The actuator is actually their Odyssey XL line and designed for platform use. So different than the ebay auction. It may have actually been a DEMO system that D-Box lent out to a high-end store.
I wasn't looking for free service on the unit, but I thought the $1,000 repair fee was a hefty charge and plus given my situation of not having it officially installed in the theater, that it might have some weight. I've only found 2 or 3 people with issues on the forums. 2 of 3 had theirs repaired for free due to manufacturer assembly or something. I've sent the information to D-Box in hopes that they can honor the same for me...but like I said, I never heard back.
It was helpful to see those diagrams of the construction, but not enough to see what might it take to repair them.
I do use Newtek's Lightwave3D for the renders.
Thanks for the compliments on the wood work.