I would much rather see the outcome of you explaining to the Dr to replace his sorry implant than see this restored... but the reality is, the Dr will send this to another lab 9 times out of 10 if you give it back to him.
if that truly is the case, i would think it ethically better to cut the loss at this point rather than continue down this line and encourage business irrespective of following practical guidelines.
recently i got a model from a certain doctor. he requested we scan it for him and send him the STL file. fine. 2 bucks later his email ringer dings.
3 months later he sends us a request to remove one of the teeth, scan again, and email him. fine.
now he wants to make an implant jig. his prescription is clearly marked "i do not use any software" and this has set off several alarm bells - as not only now does he think that by scanning a model, it qualifies as a digital representation of the caliber of a CT scan, but also qualifies as enough of a diagnostic tool to assess the patient for an implant.
clearly this guy is far misled about the nature of digital dentistry. for it, we must either re-educate him or cut off this bad apple.
he's old enough and stuck up enough to say re-education isnt a priority. had he been in his 30's or even remotely fresh out of school then this might be a worthy time-waster. this doc has his nose in the air as though he knows this case will go ahead without a hitch. its a cut that must be made before he makes an enormous cut in a patient.
i'd advise you to consider the same; consider re-education in the use of implant jigs, or consider letting this bad apple float about from lab to lab. either that or charge a large premium to fix this case (one that will cover legal fees in a malpractice suit). the cost of not following proper healthily documented procedure.