After two months of emails Porter Cable responded today admitting the defects in quality of the 890 series router bases. To view the official response click here:
http://www.routerforums.com/40327-post40.html
As they resolve the quality issues I will update this posting. The entire plunge base tooling has been scrapped and a new design from a new supplier is in process. New units should be available in the next two months. I have requested information on how to go about getting a repair or replacement and will also post that here when I receive it.