I have purchased and currently own a good number of House of Staunton Chess sets, boards and bags.
I first began working with Frank Camaratta in 1998. I would talk with Frank on the phone and he would tell me of sets he was coming out with. I would buy them, sometimes sight unseen. The quality of the sets and boards and their bags has always been very high.
Yes, Frank did sell the company quite a few years ago to Shawn Sullivan. For a bit of time before the sale, Shawn was the manager of the place for Frank.
The thing is that they have the equipment made overseas, except for a few occasions of boards, but I do think a good number of the boards are also made overseas.
The sets are made in India. I recall when Shawn first took over, him and/or Frank finding different manufacturers for the sets. At about that time I coincidentally sold off most of my better sets and boards to make my “collection” something I would use for play a lot more. I also gave a set to my brother in law. What I found when I later bought some sets to replace the ones I found I really missed was that the quality of the newer manufactured sets was quite a bit better than the originals. For instance the Liberty Series set that I originally bought was one of the first 2 or 3 that Frank had made in Rosewood. The newer set had the pieces be a lot more robust and of a nicer quality manufacture.
The same was true for some of the boards. For instance they sell a board called the Superior Traditional with the playing surface recessed in the frame. I had problems with the surface of a couple of squares showing flaws in the original board and Frank had me send it back with the replacement being a lot thinner wood and not as nice of a build. Well Shawn found a different manufacturer for the board when he took over, in England I believe, and a guy I know bought one and it is of the better quality thickness and build of the first ones.
So, I think that Shawn has had good quality sets and boards in his tenure of owning the company.
I read the linked chess.com forum and yes, it does appear they had some problems with either the manufacture or packaging of the sets. However, I have never had a problem with the House of Staunton not standing behind their product.
In the case of the guy buying the Grandmaster Series set and the $40 board, I can see his problem. First off the $40 board is most likely the one made in Poland or some other Eastern European country. Those boards are the ones commonly known as the Bundesliga boards, because they are used in that European league. I own 3 of those boards, two folding and one regular. For $40 there is no way the board could be solid wood. Of course it is veneer. For this guy to expect solid wood at that price is kind of ridiculous. Sure he mentioned that he understood it was veneer for the price but was still not satisfied with it because it was not solid wood. I am sure HOS would gladly replace the veneer board that had a chip on the corner with no problem.
The set he bought is one of the least costing sets they sell. When I sold off my more expensive sets, I gradually replaced them with the lesser costing sets and I have to say those sets are great for playing with and really do compete with their sets costing 3 times or more in play. Of course the fine detail of the sets is not what the more expensive sets have, but you do get what you pay for. I currently have only one of their sets in their higher price range and that is a 4" Morphy Series set in Blood Rosewood. That’s my really nice set and they list that for over $800. All my other sets of theirs retail for less than $150. That notwithstanding, the Proline Series set really rivals their Marshall Series set and 3 times the cost. Their Classic Series set at 3.75" rivals their Player Series and Professional Series sets at about 2 times and more the cost. Their Zagreb '59 Series set is nice and fun and their Championship Series set, which is one of their cheapest, is a duplicate of the DGT Board standard set and looks and plays just fine for just a little over $50.
It sounds as if the set that guy got had a batch problem with the glue on it and not being cleaned or finished that well. I bet if he would have talked with them in a more working kind of way, he would have been satisfied. Instead he asked for a refund. I know that whenever I call them with any kind of a problem they are good.