Bummer!
However as my previous employer liked to say - it's another opportunity for excellence!
Seriously though, we all appreciate you taking the lead on this.
I've been thinking about how I would build one, and had decided that I would like to try gluing from the back using silicone - would ensure a complete seal as well as gluing. Some masking tape from the front would hold the floor plates during drying.
This would also allow some gap-filling opportunities.
You might be able to recut the problem slots and use silicone to take care of the extra slop, thus salvaging the project.
A new jig to stop the errors adding could also be worth developing. Completely understand if you've had a gutful though...