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It's great when a vendor stands behind their product - no issues here. Thank you for all the responses, there is a new wrench on the way - PM me with any questions!
Is it an AI wrench or after market wrench? There's a couple of things that could be happening but the long and the short of it is the flat plate under a load deformed the edge of the slot. Need to know who made it.
So I'm probably using the exact same setup as you. Tubbs and probably the same vendor of action wrench.
Having the rifle "locked" into the vise is only have of what you need to do. If you don't support the butt of the weapon and make sure its straight when you try to break or lock in a barrel you run the risk of screwing up the threads on the barrel or action.
On AI rifles I use wrenches I made here in the shop out of 4140HT steel. Even with steel that tough I've flaired the slot from time to time. Now I basicaly chamfer the edge of the slot by milling a small flat across the opening and make sure the plate is fully inserted into the slot. You could do the same thing by filing a flat across the slot. That relieves the edges in case they get deformed.