Wow! Do you deliver these cases in person, or is it shipped. Maybe bringing all the models and restorations into the office would help the dentist learn from it. Present it like this "Dr. I really want this case to go well for you, as I know how frustrating remakes are for all of us. This patient sounds like a challenge. I need to sit down with you and look over this case so we can get the best outcome possible." try and be neutral. A gagging patient that throws up during impressions has to be a challenge for the dentist too, but you can't make a miracle from manure. When a dentist looks at a case you have poured up they often see things they did not see in a gagging or difficult patient because they wanted to get the heck out of there. If your Dr. realizes that your doing your best work with what you have been given maybe he will consider a new impression. The digital impression may be the best. I know one labs remake policy is 50/50 no matter who is at fault, but they don't keep a dentist if their work is not up to par. This dentist probably knows exactly why those crowns don't fit. He doesn't want this patient costing him any more, selfish I know, but he probably spent twice as long with them in the chair on the initial prep and impression. What I am saying is you got a giant pile of junk, it is not your fault, let the dentist see what he has done to you, and allow him to take some ownership. Don't be confrontational, just give him the facts and ask him for "ideas" so he can think about the why.