Diggin up this slightly older thread for my 2 cents...
For starters, thanks for the feedback datobin1. I'm glad you were able to get a better unit.
For everyone else.... don't stress about it too much. Here's my take on it,
I finally got mine set up and running this weekend.

I'M IN LOVE WITH THE BIG SCREEN! haha... 100" of bliss @10' sitting & 15' projection... but now for the "picky" part. I do have a slight alignment issue (i guess). I got my HTPC rigged up and if I walk up to the screen when a website like AVS up, I see the red, green, blue on the dotted "i"'s and some other text. Step back a foot or two and its not noticeable. So how many sit that close to the screen? ... Anyone? haha

I look at this as only being an issue if you want it to be an issue. Reminds me of the old debate of LCD back-light for the Dell Ultrasharp 20" screens when they first hit the market 5 years ago. I bought 2 from the first generation. (still using today) They have a little back light in the corners, if you are looking at a blank screen. But the moment you input a signal/picture, you don't notice it. Same as this alignment issue. Once you sit back at a typical viewing distance, or even closer, and/or watch some programing, you won't notice it. Can it be better? sure, perfection is better ... but it definitely can be worse!... how about 2-5 pixels off!? That could suck.
So, yes, I have a pixel or two alignment issue. Does it bother me? Heck no! To think I was really getting worried and stressed about this for the last month or so while I prepared my room. I don't even notice it unless I look for it from up close. I don't plan on using this for my PC needs, but only for Prime-Time TV & Movies. Its not made for doing my Autocad/GIS design work on ...(hmm... that could be cool

), that's what a desktop is for. It just doesn't effect me enough to go through the exchange process... hoping for better projector but likely to get worse.
... Perhaps my vision isn't as good as others. Here I am sitting on the sofa typing this on the 100" beast and I don't notice a blemish. At 1920x1080 resolution, I need my "driving" glasses on to even read this small text. I don't need glasses to enjoy a movie. These glasses are only for my driving needs as I'm "near-sighted", very slightly.
So I would like to sum this up and say... don't stress about it too much. For this price, with this much performance, i don't see a pixel or so off being an issue ... two or more, maybe try an exchange, but one off is pretty damn sweet if you ask me.
*EDIT.... A few hours after this post, I just got done tweaking my settings a bit more. Found a menu I didn't notice before for additional "sharpness" tweaks. In the menu, you are defaulted to the STANDARD view. Click on that to go to the Advanced menu where you will now have 4 additional sliders to play with. The bottom two tweak the vertical and horizontal sharpness. After tweaking these, I couldn't be more satisfied. It almost eliminated any alignment issues i thought I had. Just a slight blur of color around the "box" now instead of the pixel width coloring. I set my Ver to 7 and horz to 2 initially. Then I tweaked the contrast and brightness just a bit and returned to adjust the vert/horz to 3 (vert) and -1 (horz). I also slid the "Thin Line Enhancement" to 0. I'll post the rest of my settings in the Epson 8100 Owners thread shortly. Right now... i got to get back to the football game.