The lens came back last Friday but I haven't touched my camera in that time. Sigma put the lens on a K3 (I have a K3 II) and performed a calibration. I just now grabbed the focusing chart, tripod, camera, and stepped onto the porch to give it a quick test. Focus was obtained on the first try in full auto. Switch to manual and adjust focus closer / further and it missed focus once. Hmm, full auto. Not sure it was actually focusing on the exact same spot both times so switch to AV, spot focus, and f2.8. Obtain focus, try again and no change. Manually change focus and same results. Did this several times. Change to f3.5 and repeat. f5.6, f8. f11, f22 and there was a total on one adjustment after initial focus was obtained. So I'd say the lens is now working 95% better. Not as well as the newer, more expensive Pentax lenses but well enough that I can't complain. I should have sent it off two years ago...
And last night I realized something embarrassing. I have my own .US and .ME domains so I create email aliases for specific purposes.
sigma@my_domain.us and such so I can kill any which get passed off to overly enthusiastic marketing departments. Well, when I emailed Cris Cam I created an actual address, not an alias. So I was checking the main account and it never arrived because I clicked the wrong button. So they replied in 3 hours and I complained they didn't respond. I try to not be a jerk but I guess I occasionally fail.