The short version is that the lifter trays I got from Vinci were junk. He claimed they were OEM, but they're absolutely not. They're not even the same color as OEM trays. They never did hold the lifters securely when they were new, and I didn't know enough to know that wasn't okay. So they allowed the lifters to twist - especially at higher RPM. That twisting chipped the edges of some of the rollers until they got loud and also started to wipe the cam. Happened to 2 cams before I figured out what was going on. I bought new OEM trays for this 3rd swap and there is no comparison between how thick the plastic is on the OEM trays, and how tightly they hold the lifters when compared to Vinci's. I've shown the difference here in a video:
I'm sad not because I had to do the job 3 times (although that sucked), but because I trusted Roger at his word longer than I should have, and also that I didn't have the experience to know when to follow my instincts and stick to my guns. That part is on me.
His cam and support along the way were top-notch, and he warrantied the cam, but the pattern was continual denial that there could be any problems with his lifters or trays, which led me to keep trying and reusing the trays. After the first cam failed and I inspected the 2 damaged lifters and lobes, I suspected that the lifters were twisting in the bores because the damage was consistent with that and the trays felt loose to me. Also, the rollers on his lifters were a few mm narrower than the Morels or OEM lifters at the contact point with the cam, which would serve to amplify the effects of any twisting motion. I even diligently sent Roger the failed lifters and he claimed it was FOD that caused the failures, but I had an experienced builder here in Richmond look at the pictures (as well as put eyes directly on the 2nd cam and set of lifters I pulled out) and he said that it was clearly damage from twisting in the trays. And, I am fanatical about cleanliness when I work, so while the chance of FOD isn't zero, it's unlikely. The trays are the proverbial smoking gun. I also had one of the lifters in the batch he sent me that wouldn't fit in the bore, which should have been a red flag to me. I accept that any vendor can get a bad batch of parts, but the correct solution is to own up to it when presented with the evidence.