So many steps, so many variables.
Acrylic areas can lock into undercuts that are not present when metal framework alone
not have interference with. Stone model, after processing, would typically be abraded
or have teeth fractured. Person seating RPD may not know how to use 'rotational' path
or know where to relieve and give up readily.
Again, so many steps, so many variables.
LCM
All good info here,
Also the obvious, it didn't really fit great at try in and the the client missed it. A lot of times when there are only a few teeth like this when its just sent for frame try in the rest seats are close the frame almost fits and it appears that it will work to the client. Then you put teeth on and process and the client calls you saying the teeth are longer than the adjacent teeth and the frame isn't seating. Well duh it never seated flush in the first place.
I had a client, HAD being the key words, that liked to survey and design all of his partials. Yes yes there are a few clients that know their responsibility even if its not a benefit to the patient. Anyhow he had a basic understanding of the use of a surveyor from school but really did not understand rotational paths let alone the best clasp designs for the existing dentition. Just because a book says that a free end case should have an I-bar doesn't mean the undercut is in the right place. Anyhow I digress, he would have us pour mount and send his models to him to do the survey/design, we would block out to his markings and cast, he was so anal about fit that he did not want us to use an electric polishing unit and made us hand polish everything and leave the tissue bearing surface raw on Max cases. After all of the head aches he would then do his own bite rims on the frame and many times the wax would flow under the frame and keep the frame from seating properly. He would not allow any tissue stops on frames as " they were just an adjustment nightmare" So after working with this guy for about 6 months I just flat gave up as we had so many issues with his beliefs.
As for you situation, if you are pouring the master model make sure its just that, "a master model" and not something that the frame can abrade by being rough with it. I make a silicone mold that I can pour multiple models from and always have the first pour to verify after we have worked out all fitting on other casts.
OK after writing this out I realized this probably has no interest to anyone but it did make me feel better remembering how I cut him loose