Sorry. I read your original post as saying the fork was sent back with diffferent coloured decals. Now I've re-read it, and if I have it correct that they sent you back a completely different coloured lower leg assembly then yes. I'd absolutely agree you have good reason to complain.
what colour were the original lowers? If a custom colour I can understand how SRAM could not replace like for like (but i'd also have expected them to have told you this), if your OEM lowers were standard black and they sent you a completely different replacement colour not so much.
240lb is quite heavy for a mountainbike rider. You'll find difficulty in choosing off the shelf suspension products to work well at either end of the rider weight scale as they're a general product made to fit a spectrum of weights. (but all not all that wide).
one of the reasons your damping is weak on large hits is due to you using tokens. tokens ramp up the spring rate in the final portion of travel quite considerably so (obvz) more rebound damping will be required to control it.
you're not stirring anything up. I'm just stuck indoors with coronavirus. Your fork issues don't really register on my scale of fucks given right now.
Read the RS35 description you quoted again. But this time try to read it from the perspective of a 170lb rider who currently rides a RS 30. (the 30mm stanchion equivalent).
Yeah. Mail order on discount from Merlin Cycles in 1996 maybe
There's a suspension set-up guide stickied at the top of the general forum that might help you both.