Well, speaking of "sending the message to Hasbro," why don't you
literally send a message with your grievances? They do actually take some degree of notice of that. Best to include a photo of the scale as evidence.
1. Well, that is disappointing. But you say "A traditional deluxe"... Is that including WFC and SS/SS86 Deluxes? Those are the most accurate thing to compare him with, as they are contemporary. And they typically have a lot more visible hollows and exposed mushroom pegs than SS86 Hot Rod does. As do some of those Voyagers you mentioned. SS86 Hot Rod also has a higher accessory count than many contemporary regular-retail Deluxes - two guns, a saw with a rotating blade, a Matrix of Leadership, and three blast effects.
2a. Joint colors generally don't get priority on normal figures, no matter how much they cost for their size. Especially since these days, joints (particularly on smaller figures, speaking from my experience as a customizer) are sometimes
manufactured from a different plastic than the main body pieces for tolerance reasons. Which I strongly suspect is the case with SS86 Hot Rod: His spoiler (which is single-strut like PotP's, which I know did this) and the yellow joint pieces look to not have the same gloss sheen as most of his parts do, same for the gray used for the hands, the elbows, and the struts for the arm pipes. If that
is the case, then the legs you are sooooo convinced will break very fast are probably going to hold up quite well in reality. As for not getting the Magenta body color right, well... HasTak obviously have a
severe mental block about that considering that not even the bloody MASTERPIECE line has gotten that right.
2b. Is the front really too short tho? The flame section alone is at least as long as the windshield. And again, stuff does have to fit for transformation.
3. I suppose I'm going to have to see for myself regarding the arms. But I suspect these apparent limits stem from trying to be accurate to Hot Rod's visual design and keep the tops of his shoulders from going above the neckline too much. Doing that while having articulated shoulders cannot
possibly play nice with how the arms are used in car mode - there's a reason other CHUG Hot Rods compromise on it (Classics and TR both gave up completely, with the shoulders going above the head) - and he lacks the size and budget to deal with it the way the MPs do.
4a. "Not hollow, big deal. That is just how the molding is injected." No, it's how the molding is
cut. Not hollow =/= the same mold with more plastic into it, which is what I'm assuming your meaning. In most cases it's also how the toy is
assembled, which is something I don't think we think about a lot.
Example: the thigh hollows that have become ubiquitous these days save money not simply because of using less mass, but because they also save on engineering costs and assembly labor by allowing the body of the thigh to be a single piece (which requires only a single pair of cutouts in the mold and can be pegged and pinned into place as-is). Enclosed thighs require
two pieces (because articulation - if they were one piece, you couldn't still have the mushroom-pegged bicep swivel; SS86 Kup gets around this laterally by having 5mm peg bicep swivels, but do we want that on most figures?), which means making two pairs of cutouts in the mold, and the extra labor cost of screwing or pinning those pieces together.
4b. The visor breaking off is disappointing (if not surprising given the size - smol clear plastic bit =/= rugged), but making it an actual integrated part of the head
is still more complex engineering than normal. There is no possible way that you can rationally say it isn't.
4c. Hot Rod also goes out of the way to have the car kibble on his legs hidden away, and has the same kind of business going on with his thighs as SIEGE/ER Optimus, which is more than can be said for Deluxes
or most Voyagers. And need I remind you, he has articulated hands. Perhaps none of that is "special" per se, but it's still a higher complexity level especially for the size.
As for "you'll never get it back"... Given that the Kingdom and other SS86 Voyagers are
all within the norms, I seriously doubt SS86 Hot Rod is the harbinger of doom you're making him out to be.
I'm pretty sure that he's just HasTak using a Voyager development budget laterally in order to give us as premium and accurate a Hot Rod as could be managed within retail limits, because Hot Rod was the star of the movie, and future Voyagers will continue to be in the usual vein of the price point.
I'd actually offer to buy yours, since you hate him so much, but you live in Canada which would likely make the shipping stupid AF.